Hydraulic bicycle hose structure

ABSTRACT

A hydraulic bicycle hose structure includes a hydraulic hose and a first seal. The hydraulic hose has a first end with a first opening. The hydraulic hose is configured to be coupled to a hydraulic component. The hydraulic hose is filled with hydraulic fluid. The first seal is arranged to seal the first opening of the first end of the hydraulic hose. The first seal is configured to be physically ruptured.

BACKGROUND

1. Field of the Invention

This invention generally relates to a hydraulic bicycle hose structure.More specifically, this invention relates to a hydraulic bicycle hosestructure that is used in a hydraulic bicycle system.

2. Background Information

A hydraulic brake system is well known as an example of a bicyclehydraulic system. The hydraulic brake system for a bicycle typically hasa brake lever that is fluidly coupled to a brake caliper by a hydraulicbrake hose. The brake caliper is hydraulically controlled by hydraulicfluid flowing through the hydraulic brake hose in response to operationof the brake lever. In particular, operation of the brake lever forceshydraulic fluid through the hydraulic brake hose to the brake caliper.The hydraulic fluid then moves one of more pistons to cause the brakepads to squeeze a rotor that is attached to a hub of a bicycle wheel. Toensure proper operation of the hydraulic brake system or other hydraulicbicycle system, air in he hydraulic bicycle system should be removed.

SUMMARY

One aspect is to provide to a hydraulic bicycle hose structure that aidsin avoiding air being trapped in a hydraulic bicycle system duringassembly.

In view of the state of the known technology, a hydraulic bicycle hosestructure is provided that basically includes a hydraulic hose and afirst seal. The hydraulic hose has a first end with a first opening. Thehydraulic hose is configured to be coupled to a hydraulic component. Thehydraulic hose is filled with hydraulic fluid. The first seal isarranged to seal the first opening of the first end of the hydraulichose. The first seal is configured to be physically ruptured.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of thisoriginal disclosure:

FIG. 1 is a side elevational view of a disc brake assembly using ahydraulic bicycle system with a hydraulic brake hose structure between abrake operating mechanism and a brake caliper in accordance with oneembodiment;

FIG. 2A is a partial cross-sectional view of the hydraulic brake hosestructure illustrated in FIG. 1, with the hydraulic brake hose structurehydraulically connected to the brake operating mechanism and the brakecaliper in the hydraulic brake system;

FIG. 2B is a enlarged partial cross-sectional view of encircle portionsIIB in FIG. 2A;

FIG. 3 is a partial cross-sectional view of the hydraulic brake hosestructure illustrated in FIG. 1, with both ends of the hydraulic brakehose structure sealed with sealing materials;

FIG. 4 is an enlarged perspective view of one end of the hydraulic brakehose structure illustrated in FIG. 3;

FIG. 5 is an enlarged, partial cross-sectional view of the brakeoperating mechanism illustrated in FIGS. 1 and 2, with a hose attachmentbore of the brake operating mechanism sealed with a sealing material;

FIG. 6 is an enlarged, partial cross-sectional view of the brake caliperillustrated in FIGS. 1 and 2, with a hose attachment bore of the brakecaliper sealed with a sealing material;

FIG. 7 is a partial perspective view of the brake operating mechanism,illustrating a threaded fitting and a tubular bushing attached to anassembling jig for assembly;

FIG. 8 is a partial cross-sectional view of the brake operatingmechanism, illustrating the threaded fitting and the tubular bushingattached to the assembling jig for assembly;

FIG. 9 is a partial cross-sectional view of the brake operatingmechanism, illustrating the assembling jig with the threaded fitting andthe tubular bushing inserted to a hose attachment section;

FIG. 10 is a partial cross-sectional view of the brake operatingmechanism, illustrating an end of the threaded fitting that has beencoupled to the hose attachment section sealed with a sealing material;

FIG. 11 is a partial cross-sectional view of the brake operatingmechanism, with the brake operating mechanism coupled to the hydraulicbrake hose structure;

FIG. 12 is a partial perspective view of the hydraulic brake hosestructure illustrated in FIG. 3, with a protective cap coupled to oneend of the hydraulic brake hose structure;

FIG. 13 is a partial cross-sectional view of the hydraulic brake hosestructure illustrated in FIG. 12, with the protective cap coupled to oneend of the hydraulic brake hose structure;

FIG. 14 is a partial perspective view of the hydraulic brake hosestructure illustrated in FIG. 12, with a cord attached to the protectivecap;

FIG. 15 is a top plan view of the brake operating mechanism illustratedin FIG. 1, with a lever stopper coupled to the brake operatingmechanism;

FIG. 16 is a partial cross-sectional view of the brake operatingmechanism illustrated in FIG. 15, with the lever stopper coupled to thebrake operating mechanism;

FIG. 17 is a side view of the brake operating mechanism illustrated inFIG. 15, with the lever stopper coupled to the brake operatingmechanism;

FIG. 18 is an enlarged, partial cross-sectional view of the brakeoperating mechanism illustrated in FIGS. 1 and 2, with the hoseattachment bore of the brake operating mechanism sealed with a sealingplug;

FIG. 19 is an enlarged, partial cross-sectional view of the brakeoperating mechanism illustrated in FIGS. 1 and 2, with the hoseattachment bore of the brake operating mechanism sealed with a modifiedsealing plug;

FIG. 20 is a side elevational view of a disc brake assembly using ahydraulic brake system in accordance with a modified example, with apair of hydraulic brake hose structures of the brake operating mechanismand the brake caliper coupled to each other via a hydraulic hosecoupler;

FIG. 21 is a cross-sectional view of the hydraulic hose couplerillustrated in FIG. 20;

FIG. 22 is a partial cross-sectional view of the hydraulic brake hosestructure with a modified protective cap coupled to one end of thehydraulic brake hose structure;

FIG. 23 is an enlarged, partial cross-sectional view of the brakeoperating mechanism illustrated in FIGS. 1 and 2, with a modified leverstopper coupled to the brake operating mechanism;

FIG. 24 is a perspective view of the modified lever stopper illustratedin FIG. 23;

FIG. 25 is a perspective view of the modified lever stopper illustratedin FIG. 23;

FIG. 26 is an enlarged, partial perspective view of the brake operatingmechanism illustrated in FIG. 23, illustrating assembly of the modifiedlever stopper illustrated in FIGS. 24 and 25 to the brake operatingmechanism;

FIG. 27 is an enlarged, partial perspective view of the brake operatingmechanism illustrated in FIG. 23, illustrating assembly of the modifiedlever stopper illustrated in FIGS. 24 and 25 to the brake operatingmechanism;

FIG. 28 is a perspective view of a brake operating mechanism inaccordance with a modified example, with a modified lever stoppercoupled to the brake operating mechanism;

FIG. 29 is an enlarged, partial cross-sectional view of the brakeoperating mechanism illustrated in FIG. 28, with the modified leverstopper coupled to the brake operating mechanism;

FIG. 30 is a perspective view of the modified lever stopper illustratedin FIGS. 28 and 29;

FIG. 31 is a partial cross-sectional view of the hydraulic brake hosestructure with a modified sealing material;

FIG. 32 is a partial cross-sectional view of the hydraulic brake hosestructure with a modified sealing plug;

FIG. 33 is a cross-sectional view of a rupturing tool for rupturing thesealing material of the hydraulic brake hose structure;

FIG. 34 is a top plan view of a hydraulic operating mechanism inaccordance with a modified example of the embodiment; and

FIG. 35 is a partial cross-sectional view of the bicycle operatingmechanism, with the bicycle operating mechanism coupled to a hydraulicbicycle hose structure.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments will now be explained with reference to thedrawings. It will be apparent to those skilled in the art from thisdisclosure that the following descriptions of the embodiments areprovided for illustration only and not for the purpose of limiting theinvention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1, a disc brake assembly 10 is illustratedthat includes with a hydraulic brake system 12 with a hydraulic brakehose structure 14 (e.g., a hydraulic bicycle hose structure) inaccordance with one illustrated embodiment. As discussed below, thehydraulic brake hose structure 14 is prefilled with hydraulic fluid andsealed at each end so that the hydraulic brake system 12 can beassembled in a relatively easy manner without air being trapped in thehydraulic brake system 12.

While the hydraulic brake hose structure 14 is illustrated as being usedwith a rear disc brake assembly, the hydraulic brake hose structure 14can also be used with a front disc brake assembly. The disc brakeassembly 10 has a disc brake rotor 16 that is fixedly attached to a hub18 of a bicycle wheel (not shown). The hydraulic brake system 12 furtherincludes a brake operating mechanism 20 (e.g., a hydraulic component ora first hydraulic component) and a brake caliper 22 (e.g., a hydrauliccomponent or a second hydraulic component). The caliper 22 and the brakeoperating mechanism 20 include conventional bicycle components that arehydraulically operated in a conventional manner, unless otherwisespecified below. Since these components are conventional, they will notbe discussed and/or illustrated in detail herein. Furthermore, the discbrake assembly 110 is installed to a bicycle. Bicycles and their variouscomponents are well-known in the prior art, and thus, the bicycles andits various components will not be discussed or illustrated in detailherein, except for the components of the disc brake assembly 10. Inother words, only the disc brake assembly 10 will be discussed andillustrated in detail herein. Moreover, since most disc brake assembliesare well known to those skilled in the art, the disc brake assembly 10will only be discussed and illustrated to the extent needed tounderstand the present disclosure.

As seen in FIG. 1, the brake operating mechanism 20 basically has abrake housing 23 with a master cylinder 24. The brake operatingmechanism 20 further has a clamp 26 and a brake lever 28. The clamp 26is integrally formed with the brake housing 23. The brake lever 28 ispivotally coupled to the brake housing 23. The brake operating mechanism20 is supported on a handlebar 30 via the clamp 26 in a conventionalmanner. The brake lever 28 is pivotally coupled to the brake housing 23for operating the caliper 22 as explained below. The master cylinder 24defines a master cylinder bore or chamber 32 that has a piston 34reciprocally mounted in the master cylinder bore 32. The piston 34 isbiased with a compression spring disposed within the master cylinderbore 32, The master cylinder 24 also has a hydraulic fluid reservoir 36that is in fluid communication with the master cylinder bore 32. Thehydraulic fluid reservoir 36 contains the hydraulic fluid (e.g., mineraloil) which is pressurized by movement of the piston 34 in the mastercylinder bore 32 in response to the pivotal movement of the brake lever28 towards the handlebar 30. In other words, the brake lever 28 isoperatively coupled to the piston 34 for moving the piston 34 between apiston rest position and a piston operating position. The mastercylinder 24 has an outlet port 38 (see FIG. 2A) for supplying thehydraulic fluid to the caliper 22 via the hydraulic brake hose structure14. Since the operations of the master cylinder 24 and the piston 34 areconventional, these parts will not he discussed or shown in furtherdetail herein. The master cylinder 24 also has a hose attachment section39 (e.g., an attachment portion) with an internal threaded bore 24 athat is fluidly communicated with the master cylinder bore 32 via theoutlet port 38.

Still referring to FIG. 1, the caliper 22 basically has an internalfluid passage 40 with an inlet port 42. A piston 44 is movably mountedin a cylinder defined by a housing of the caliper 22 by fluid pressureentering the internal fluid passage 40 in a conventional manner. Thecaliper 22 also has a hose attachment section 46 with an internalthreaded bore 22 a. The internal threaded bore 22 a is fluidlycommunicated with the internal fluid passage 40 via the inlet port 42.The caliper 22 is hydraulically controlled by hydraulic fluid flowingthrough the hydraulic brake hose structure 14 in response to operationof the brake lever 28 of the brake operating mechanism 20. Morespecifically, when the brake lever 28 of the brake operating mechanism20 is operated, this causes the hydraulic fluid to be pressurized andflow through the hydraulic brake hose structure 14 into the internalfluid passage 40 via the inlet port 42. In other words, operation of thebrake lever 28 forces hydraulic fluid through the hydraulic brake hosestructure 14 to the caliper 22. As a result of the operation of thebrake lever 28, the pressure in the internal fluid passage 40 increases,and thus causes the caliper 22 to apply a braking force on the diskbrake rotor 16. In particular, the hydraulic fluid then moves the piston44 to cause the brake pads (not shown) to squeeze the disk brake rotor16. Since the operations of the caliper 22 and the piston 44 areconventional, these parts will not be discussed or shown in furtherdetail herein.

Referring now to FIGS. 2A to 6, the hydraulic brake system 12 will nowbe discussed. As seen in FIG. 2A, the caliper 22 and the master cylinder24 are fluidly coupled together by the hydraulic brake hose structure14. As best seen in FIGS. 3 and 4, the hydraulic brake hose structure 14is completely prefilled with hydraulic fluid and sealed at each endprior to attachment to the caliper 22 and the master cylinder 24.Moreover, the hydraulic brake hose structure 14 is partially inserted tothe caliper 22 and the master cylinder 24 in the sealed condition suchthat the hydraulic fluid in the hydraulic brake hose structure 14 isprevented from flowing into the caliper 22 and the master cylinder 24.Furthermore, as best seen in FIG. 2B, the hydraulic brake hose structure14 is physically unsealed in response to the hydraulic brake hosestructure 14 being fully inserted to the caliper 22 and the mastercylinder 24. On the other hand, as best seen in FIGS. 5 and 6, thecaliper 22 and the master cylinder 24 are completely prefilled withhydraulic fluid and sealed at ends prior to the attachment of thehydraulic brake hose structure 14. The caliper 22 and the mastercylinder 24 are unsealed when the hydraulic brake hose structure 14 isattached to the caliper 22 and the master cylinder 24, respectively.Said shortly, as seen in FIGS. 3 to 6, the hydraulic brake hosestructure 14, the brake operating mechanism 20 and the caliper 22 arerefilled with the hydraulic fluid and sealed with sealing materials forshipment, and then are unsealed for assembling. With the hydraulic brakehose structure 14, the caliper 22 and the master cylinder 24, thehydraulic brake system 12 can be assembled in a relatively easy mannerwithout air being trapped in the hydraulic brake system 12.

Referring further to FIGS. 2A to 6, the hydraulic brake system 12 willnow be discussed in more detail. As seen in FIG. 2A, the hydraulic brakehose structure 14 basically includes a flexible tube 50 (e.g., hydraulichose) which forms an unfilled and unsealed hydraulic brake hose. Theflexible tube 50 is a conventional flexible tube that is used forconveying hydraulic fluid from the master cylinder 24 to the caliper 22under pressure. The hydraulic brake hose structure 14 is coupled to themaster cylinder 24 with a first connector 511, and is coupled to thecaliper 22 with a second connector 52. The first connector 51 isdisposed over a first end portion 50 a. of the flexible tube 50 forattachment to the master cylinder 24 of the brake operating mechanism20, while the second connector 52 is attached to a second end portion 50b of the flexible tube 50 for attachment to the caliper 22. The flexibletube 50 has an interior passage 50 c extending between the openings ofthe first and second end portions 50 a and 50 b of the flexible tube 50.

As seen in FIGS. 2A to 5, the first connector 51 basically includes afirst threaded fastening sleeve or fitting 54, a first rigid tubularinsert 56 and a first tubular bushing 58. As seen in FIG. 2A, the firstthreaded fitting 54 is a tubular member that overlies the first endportion 50 a of the flexible tube 50 while the hydraulic brake hosestructure 14 is coupled to the master cylinder 24. The first threadedfitting 54 has an externally threaded portion 54 a that is threaded intothe internal threaded bore 24 a of the master cylinder 24.

The first tubular insert 56 has an annular flange section 56 a and atubular section 56 b. A longitudinal passageway 56 c passes through thetubular section 56 b and the flange section 56 a. The outer surface ofthe tubular section 56 b has a plurality of inclined barbs such that thetubular section 56 b is securely retained in the interior passage 50 cof the flexible tube 50. The first tubular insert 56 is designed to beretained in the first end portion 50 a of the flexible tube 50 and toprovide radial support at the first end portion 50 a of the flexibletube 50. Accordingly, the first tubular insert 56 is constructed of arigid material such as a metallic material. For example, the firsttubular insert 56 can be formed of a copper or a copper alloy. Ofcourse, any suitable rigid material can be utilized for the firsttubular insert 56 as needed and/or desired.

The first tubular bushing 58 overlies the first end portion 50 a of theflexible tube 50 while the hydraulic brake hose structure 14 is coupledto the master cylinder 24. The first tubular bushing 58 is designed tobe deformed during installation of the first threaded fitting 54 intothe internal threaded bore 24 a of the master cylinder 24. Inparticular, the first tubular bushing 58 is compressed axially duringinstallation of the first threaded fitting 54 into the internal threadedbore 24 a of the master cylinder 24. As a result, the first tubularbushing 58 is deformed so as to squeeze the first end portion 50 a ofthe flexible tube 50 onto the first tubular insert 56. The first tubularbushing 58 is constructed of a rigid material such as a metallicmaterial. For example, the first tubular bushing 58 can be formed of acopper or a copper alloy. Of course, any suitable rigid material can beutilized for the first tubular bushing 58 as needed and/or desired.

As seen in FIG. 5, the first threaded fitting 54 and the first tubularbushing 58 are attached to the internal threaded bore 24 a of the mastercylinder 24 prior to the first end portion 50 a of the flexible tube 50being coupled to the hose attachment section 39 of the master cylinder24. In other words, the first threaded fitting 54 and the first tubularbushing 58 define a first hose attachment bore 51 a of the firstconnector 51 into which the first end portion 50 a of the flexible tube50 is inserted.

A flexible boot or cover 60 is optionally provided to cover the firstthreaded fitting 54. The cover 60 is preferably constructed of aflexible elastomeric material with good sealing properties, The cover 60is sized to snugly engage the first end portion 50 a of the flexibletube 50 and the first threaded fitting 54 for creating a watertight sealtherebetween.

As seen in FIG. 3, the hydraulic brake hose structure 14 also includes afirst sealing material 62 for sealing the first end portion 50 a of theflexible tube 50. The first sealing material 62 forms a first seal. Thefirst sealing material 62 is formed of a thin flexible sheet of metalfoil. The first sealing material 62 is adhesively attached to the flangesection 56 a to overlie an opening (e.g., a first opening) of thepassageway 56 c. Thus, the first sealing material 62 forms a first sealthat seals the first opening of the first end of the hydraulic hose. Inother words, in the illustrated embodiment, the opening in the flangesection 56 a of the first tubular insert 56 forms the first opening ofthe first end of the hydraulic hose.

As further seen in FIGS. 2A and 2B, the first sealing material 62 isconstructed to be ruptured or punctured with a tubular rupturing insert63 (e.g., a first seal rupturing structure or a part of the firsthydraulic component). In particular, the first sealing material 62 isphysically ruptured by the rupturing insert 63 in response to the firstend portion 50 a of the flexible tube 50 being fully inserted to thehose attachment section 39 of the master cylinder 24. The constructionof the rupturing insert 63 will be discussed in detail later.

Referring to FIGS. 2A and 2B, the first sealing material 62 preventsfluid communication between the master cylinder 24 and the passageway 56c of the first tubular insert 56 until the first sealing material 62 isruptured by the rupturing insert 63. On the other hand, in response tofully inserting the first end portion 50 a of the flexible tube 50 intothe internal threaded bore 24 a of the master cylinder 24 (or the hoseattachment bore 51 a of the first connector 51), the first sealingmaterial 62 can be easily ruptured by the rupturing insert 63.

As seen in FIGS. 2A, 2B and 5, the rupturing insert 63 has a tubular endsection 63 a, an annular flange section 63 b, and a tubular body section63 c. A longitudinal passageway 63 d passes through the end section 63a, the flange section 63 b, and the body section 63 c. The rupturinginsert 63 is coupled to the outlet port 38 of the master cylinder 24such that the longitudinal passageway 63 d is fluidly communicated withthe master cylinder bore 32 of the master cylinder 24 to define a firstfluid path of the master cylinder 24. In other words, the rupturinginsert 63 (e.g., a first seal rupturing structure) is disposed in thevicinity of the first fluid path, more specifically, on a leading edgeof the first fluid path of the master cylinder 24.

The end section 63 a is formed as a needle for rupturing or puncturingthe first sealing material 62 of the hydraulic brake hose structure 14.In particular, the end section 63 a has a beveled distal end thatpunctures the first sealing material 62 and is inserted into thepassageway 56 c of the first tubular insert 56 in response to the firstend portion 50 a of the flexible tube 50 being coupled to the internalthreaded bore 24 a of the master cylinder 24. In other words, the endsection 63 a is dimensioned such that the end section 63 a is fittedlyinserted into the passageway 56 c of the first tubular insert 56. Theflange section 63 b is rested on an annular inner end face of theinternal threaded bore 24 a of the master cylinder 24. When the firstend portion 50 a of the flexible tube 50 is coupled to the mastercylinder 24, the flange section 63 b is pushed against the annular innerend face of the internal threaded bore 24 a of the master cylinder 24,which securely retains the rupturing insert 63 relative to the outletport 38. The outer surface of the body section 63 c is fitted to theinner surface of the outlet port 38. The body section 63 c is designedto he retained in the outlet port 38. The rupturing insert 63 isconstructed of a resin material such as a plastic. Of course, anysuitable rigid material can be utilized for the rupturing insert 63 asneeded and/or desired.

As seen in FIGS. 2A to 3 and 6, the second connector 52 includes asecond threaded fastening sleeve or fitting 64, a second rigid tubularinsert 66 and a second tubular bushing 68. As seen in FIG. 2A, thesecond threaded fitting 64 is a tubular member that overlies the secondend portion 50 b of the flexible tube 50 while the hydraulic brake hosestructure 14 is coupled to the caliper 22. The second threaded fitting64 has an externally threaded portion 64 a that is threaded into theinternal threaded bore 22 a of the caliper 22.

The second tubular insert 66 has an annular flange section 66 a and atubular section 66 b. A longitudinal passageway 66 c passes through thetubular section 66 b and the flange section 66 a. The outer surface ofthe tubular section 66 b has a plurality of inclined barbs such that thetubular section 66 b is securely retained in the interior passage 50 cof the flexible tube 50. The second tubular insert 66 is designed to beretained in the second end portion 50 b of the flexible tube 50 and toprovide radial support at the second end portion 50 b of the flexibletube 50. Accordingly, the second tubular insert 66 is constructed of arigid material such as a metallic material. For example, the secondtubular insert 66 can be formed of a copper or a copper alloy. Ofcourse, any suitable rigid material can be utilized for the secondtubular insert 66 as needed and/or desired.

The second tubular bushing 68 overlies the second end portion 50 b ofthe flexible tube 50 while the hydraulic brake hose structure 14 iscoupled to the caliper 22. The second tubular bushing 68 is designed tobe deformed during installation of the second threaded fitting 64 intothe internal threaded bore 22 a of the caliper 22. In particular, thesecond tubular bushing 68 is compressed axially during installation ofthe second threaded fitting 64 into the internal threaded bore 22 a ofthe caliper 22. As a result, the second tubular bushing 68 is deformedso as to squeeze the second end portion 50 b of the flexible tube 50onto the second tubular insert 66. The second tubular bushing 68 isconstructed of a rigid material such as a metallic material. Forexample, the second tubular bushing 68 can be formed of a copper or acopper alloy. Of course, any suitable rigid material can be utilized forthe. second tubular bushing 68 as needed and/or desired.

As seen in FIG. 6, the second threaded fitting 64 and the second tubularbushing 68 are attached to the internal threaded bore 22 a of thecaliper 22 prior to the second end portion 50 b of the flexible tube 50being coupled to the hose attachment section 46 of the caliper 22. Inother words, the second threaded fitting 64 and the second tubularbushing 68 define a second hose attachment bore 52 a of the secondconnector 52 into which the second end portion 50 b of the flexible tube50 is inserted.

As seen in FIG. 3, the hydraulic brake hose structure 14 also includes asecond sealing material 72 for sealing the second end portion 50 b ofthe flexible tube 50. The second sealing material 72 forms a secondseal. The second sealing material 72. is a formed of a thin flexiblesheet of metal foil. The second sealing material 72 is adhesivelyattached to the flange section 66 a to overlie an opening (e.g., asecond opening) of the passageway 66 c. Thus, the second sealingmaterial 72 forms a second seal that seals the second opening of thesecond end of the hydraulic hose. In other words, in the illustratedembodiment, the opening in the flange section 66 a of the second tubularinsert 66 forms the second opening of the second end of the hydraulichose.

As further seen in FIGS. 2A and 2B, the second sealing material 72 isconstructed to be ruptured or punctured with a tubular rupturing insert73 (e.g., a second seal rupturing structure or a part of the secondhydraulic component). In particular, the second sealing material 72 isphysically ruptured by the rupturing insert 73 in response to the secondend portion 50 b of the flexible tube 50 being fully inserted to thehose attachment section 46 of the caliper 22. The construction of therupturing insert 73 will be discussed in detail later.

Referring to FIGS. 2A and 2B, the second sealing material 72 preventsfluid communication between the caliper 22 and the passageway 66 c ofthe second tubular insert 66 until the second sealing material 72 isruptured by the rupturing insert 73. On the other hand, in response tofully inserting the second end portion 50 b of the flexible tube 50 intothe internal threaded bore 22 a of the caliper 22 (or the hoseattachment bore 52 a of the second connector 52), the second sealingmaterial 72 can be easily ruptured by the rupturing insert 73.

As seen in FIGS. 2A, 2B and 6, the rupturing insert 73 has a tubular endsection 73 a, an annular flange section 73 b, and a tubular body section73 c. The rupturing insert 73 can be substantially identical to therupturing insert 63, except for the rupturing insert 73 beingdimensioned to be attached to the inlet port 42 of the caliper 22. Alongitudinal passageway 73 d passes through the end section 73 a, theflange section 73 b, and the body section 73 c. The rupturing insert 73is coupled to the inlet port 42 of the caliper 22 such that thelongitudinal passageway 73 d is fluidly communicated with the internalfluid passage 40 of the caliper 22 to define a second fluid path of thecaliper 22. In other words, the rupturing insert 73 (e.g., a second sealrupturing structure) is disposed in the vicinity of the second fluidpath, more specifically, on a leading edge of the second fluid path ofthe caliper 22. The second fluid path of the caliper 22 is hydraulicallyconnected with the first fluid path of the master cylinder 24.

The end section 73 a is formed as a needle for rupturing or puncturingthe second sealing material 72 of the hydraulic brake hose structure 14.In particular, the end section 73 a has a beveled distal end thatpunctures the second sealing material 72 and is inserted into thepassageway 66 c of the second tubular insert 66 in response to thesecond end portion 50 b of the flexible tube 50 being coupled to theinternal threaded bore 22 a of the caliper 22. In other words, the endsection 73 a is dimensioned such that the end section 73 a is fittedlyinserted into the passageway 66 c of the second tubular insert 66. Theflange section 73 b is rested on an annular inner end face of theinternal threaded bore 22 a of the caliper 22. When the second endportion 50 b of the flexible tube 50 is coupled to the caliper 22, theflange section 73 b is pushed against the annular inner end face of theinternal threaded bore 22 a of the caliper 22, which securely retainsthe rupturing insert 73 relative to the inlet port 42. The outer surfaceof the body section 73 c is fitted to the inner surface of the inletport 42. The body section 73 c is designed to be retained in the inletport 42. The rupturing insert 73 is constructed of a resin material suchas a plastic. Of course, any suitable rigid material can be utilized forthe rupturing insert 73 as needed and/or desired.

As seen in FIGS. 3 and 4, the hydraulic brake hose structure 14 isprefilled with hydraulic fluid and sealed at opposite ends by the firstand second sealing materials 62 and 72. Preferably, the hydraulic brakehose structure 14 is free of any air or other gas between the first andsecond sealing materials 62 and 72. In particular, the hydraulic brakehose structure 14 is prefilled with hydraulic fluid and sealed atopposite ends while shipping until the hydraulic brake hose structure 14is coupled to the caliper 22 and the master cylinder 24.

As seen in FIG. 5, the master cylinder 24 is prefilled with hydraulicfluid and sealed at an end by a third sealing material 74 (e.g., a firstseal or a third seal). Preferably, the master cylinder 24 is free of anyair or other gas within a hydraulic fluid retaining area 76 (e.g., afluid path or a first fluid path) of the master cylinder 24. Thehydraulic fluid retaining area 76 is defined by the master cylinder bore32, the hydraulic fluid reservoir 36, the outlet port 38 and the hoseattachment bore 51 a. The end of the hydraulic fluid retaining area 76is sealed by the third sealing material 74. In other words, thehydraulic fluid retaining area 76 is partially defined by the firstthreaded fitting 54 (e.g., a hydraulic hose connection end) that issealed by the third sealing material 74. The hydraulic fluid retainingarea 76 of the master cylinder 24 is refilled with hydraulic fluid andsealed at the end by the third sealing material 74 while shipping untilthe hydraulic brake hose structure 14 is coupled to the master cylinder24.

As further seen in FIG. 5, the third sealing material 74 seals an endopening of the first threaded fitting 54 that has been attached to theinternal threaded bore 24 a of the master cylinder 24. The third sealingmaterial 74 forms a third seal. The third sealing material 74 is formedof a thin flexible sheet of metal foil, The third sealing material 74 isa strippable sheet. Specifically, the third sealing material 74 isremovably or strippably attached to an annular end face 54 b of thefirst threaded fitting 54 to overlie the opening of the hose attachmentbore 51 a that is defined by the annular end face 54 b. In particular,third sealing material 74 is thermally bonded to the first threadedfitting 54. The third sealing material 74 has a stripping tab 74 a thatis held for removing the third sealing material 74 from the firstthreaded fitting 54. The stripping tab 74 a extends outward relative toan outer periphery of the first threaded fitting 54. In the illustratedembodiment, the third sealing material 74 forms a first seal that sealsan end of the fluid path of the hydraulic component. In other words, inthe illustrated embodiment, the opening in the first threaded fitting 54forms an end of the fluid path of the hydraulic component.

As seen in FIG. 6, the caliper 22 is prefilled with hydraulic fluid andsealed at an end by a fourth sealing material 84 (e.g., a first seal ora fourth seal). Preferably, the caliper 22 is free of any air or othergas within a hydraulic fluid retaining area 86 (e.g., a fluid path or asecond fluid path) of the caliper 22. The hydraulic fluid retaining area86 is defined by the internal fluid passage 40, the inlet port 42 andthe hose attachment bore 52 a. The end of the hydraulic fluid retainingarea 86 is sealed by the fourth sealing material 84. In other words, thehydraulic fluid retaining area 86 is partially defined by the secondthreaded fitting 64 (e.g., a hydraulic hose connection end) that issealed by the fourth sealing material 84. In particular, the hydraulicfluid retaining area 86 of the caliper 22 is prefilled with hydraulicfluid and sealed at the end by the fourth sealing material 84 whileshipping until the hydraulic brake hose structure 14 is coupled to thecaliper 22.

As further seen in FIG. 6, the fourth sealing material 84 seals an endopening of the second threaded fitting 64 that has been attached to theinternal threaded bore 22 a of the caliper 22. The fourth sealingmaterial 84 forms a fourth seal. The fourth sealing material 84 isformed of a thin flexible sheet of metal foil. The fourth sealingmaterial 84 is a strippable sheet. Specifically, the fourth sealingmaterial 84 is removably or strippably attached to an outside end face64 b of the second threaded fitting 64 to overlie the opening of thehose attachment bore 52 a. In particular, the fourth sealing material 84is thermally bonded to the second threaded fitting 64. The fourthsealing material 84 has a stripping tab 84 a that is held for removingthe fourth sealing material 84 from the second threaded fitting 64. Thestripping tab 84 a extends outward relative to an outer periphery of thesecond threaded fitting 64. In the illustrated embodiment, the fourthsealing material 84 forms a second seal that seals an end of the fluidpath of the hydraulic component. In other words, in the illustratedembodiment, the opening in the second threaded fitting 64 forms an endof the fluid path of the hydraulic component.

Now, a method of assembly of each of the components of the hydraulicbrake system 12, and a method of assembly of the hydraulic brake system12 will be discussed in which the hydraulic brake system 12 can beassembled in a relatively easy manner without air being trapped in thehydraulic brake system 12. Unless otherwise specified, the followingmethod of assembling the hydraulic brake system 12 can be performed in adifferent order than discussed herein. In other words, the method ofassembling the hydraulic brake system 12 is not limited to the followingdescribed order of assembly unless otherwise specified. As seen in FIG.3, in the illustrated embodiment, the flexible tube 50 is completelyfilled with hydraulic fluid and the opposite ends of the flexible tube50 are sealed. In particular, the first and second sealing materials 62and 72 are attached to the flange sections 56 a and 66 a of the firstand second tubular inserts 56 and 66 after the flexible tube 50 iscompletely filled with hydraulic fluid. In this way, the first andsecond sealing materials 62 and 72 cover and seal the first and secondopenings of the first and second ends of the hydraulic brake hose forconfining the hydraulic fluid within the flexible tube 50.

Furthermore, as seen in FIG. 5, the master cylinder 24 filled withhydraulic fluid is provided. Also, as seen in FIG. 6, the caliper 22filled with hydraulic fluid is provided. Referring to FIGS. 7 to 11, amethod for providing the master cylinder 24 that is filled withhydraulic fluid will be discussed in detail. First, as seen in FIGS. 7and 8, the first threaded fitting 54 and the first tubular bushing 58are axially placed on a tubular assembling jig 88. The assembling jig 88has about the same diameter as or slightly larger diameter than theflexible tube 50. The assembling jig 88 is constructed of a rigidmaterial such as a resin material. Of course, any suitable material canbe utilized for the assembling jig 88 for supporting the first threadedfitting 54 and the first tubular bushing 58 as needed and/or desired.Furthermore, the rupturing insert 63 is attached to the outlet port 38of the master cylinder 24. Then, the first threaded fitting 54 and thefirst tubular hushing 58 are placed and positioned relative to the hoseattachment section 39 of the master cylinder 24 with the assembling jig88. In particular, the assembling jig 88 is inserted into the hoseattachment section 39 of the master cylinder 24 such that the assemblingjig 88 is concentrically arranged relative to the hose attachmentsection 39 of the master cylinder 24. With this assembly method, beforeplacing the first threaded fitting 54 and the first tubular bushing 58into the hose attachment section 39 of the master cylinder 24, the firstthreaded fitting 54 and the first tabular bushing 58 is placed on theassembling jig 88. Thus, all the parts of the master cylinder 24 can beproperly assembled without missing any parts of the master cylinder 24.

Next, as seen in FIG. 9, the first threaded fitting 54 is fastened tothe hose attachment section 39 of the master cylinder 24 with guidanceof the assembling jig 88. In particular, the threaded portion 54 a ofthe first threaded fitting 54 is threaded into the internal threadedbore 24 a of the master cylinder 24 with a predetermined tighteningtorque (e.g., a first predetermined fastening force). This predeterminedtightening torque is smaller than a final tightening torque (e.g., asecond predetermined fastening force) that is applied to the firstthreaded fitting 54 for securely coupling the first end portion 50 a ofthe flexible tube 50 to the hose attachment section 39 of the mastercylinder 24 by deforming the first tubular bushing 58. Morespecifically, with this predetermined tightening torque, the firsttubular bushing 58 is slightly deformed such that an elastic deformationor a plastic deformation occurs on the first tubular bushing 58. Afterthis slight deformation of the first tubular bushing 58, a hoseconnecting hole 58 a of the first tubular bushing 58 still has an innerdiameter such that the first end portion 50 a of the flexible tube 50can be inserted through the hose connecting hole 58 a of the firsttubular bushing 58. More specifically, after this deformation, the firsttubular bushing 58 still has an inner diameter that is equal to orlarger than the diameter of the first end portion 50 a of the flexibletube 50. With this deformation, the first tubular hushing 58 axiallypresses the first threaded fitting 54 away from the first tubularbushing 58. Thus, although the first threaded fitting 54 is fastened tothe hose attachment section 39 of the master cylinder 24 with thepredetermined tightening torque smaller than the final tighteningtorque, the first threaded fitting 54 is securely coupled to the hoseattachment section 39 of the master cylinder 24 without any loose. Inthis illustrated embodiment, before the first threaded fitting 54 isfastened to the hose attachment section 39 of the master cylinder 24,liquid gasket or other sealing materials is applied between the threadedportion 54 a of the first threaded fitting 54 and the internal threadedbore 24 a of the master cylinder 24 for preventing leakage of thehydraulic fluid between the threaded portion 54 a of the first threadedfitting 54 and the internal threaded bore 24 a of the master cylinder24.

Next, as illustrated in FIG. 10, the assembling jig 88 is removed fromthe hose attachment bore 51 a. Furthermore, the opening of the hoseattachment bore 51 a is sealed with the third sealing material 74. Thethird sealing material 74 is thermally bonded to the annular end face 54b of the first threaded fitting 54 to form the enclosed or sealedhydraulic fluid retaining area 76 of the master cylinder 24. Next, thehydraulic fluid retaining area 76 of the master cylinder 24 is filledwith hydraulic The hydraulic fluid is poured into the enclosed hydraulicfluid retaining area 76 through an oil port of the hydraulic fluidreservoir 36 (see FIG. 1) of the master cylinder 24, for example. Then,a bleed screw with an O-ring is threadedly coupled to the oil port ofthe hydraulic fluid reservoir 36.

With this assembling method, the master cylinder 24 can be filled withhydraulic fluid and sealed. Since the master cylinder 24 is filled withhydraulic fluid, less effort is necessary to fill hydraulic fluid whilehydraulically connecting the master cylinder 24 to the hydraulic brakehose structure 14. Thus, the hydraulic brake system 12 can be assembledin a relatively easy manner without air being trapped in the hydraulicbrake system 12.

The caliper 22 can also be assembled with the second threaded fitting 64and the second tubular bushing 68 with the assembling jig 88, sealedwith the fourth sealing material 84, and filled with hydraulic fluid inthe same matter described through reference to FIGS. 7 to 11 for themaster cylinder 24. Since the method of assembling of the caliper 22 isapparent from the disclosure for the master cylinder 24, the detaileddescription of the steps of assembling of the caliper 22 is omitted forthe sake of brevity. As a result, the hydraulic brake hose structure 14,the caliper 22 and the master cylinder 24 are independently filled withhydraulic fluid and sealed. These components form a hydraulic brake kit(e.g., hydraulic component kit).

Next, the hydraulic brake hose structure 1.4 is hydraulically connectedto the caliper 22 and the master cylinder 24. Referring to FIG. 11, amethod of assembling the hydraulic brake hose structure 14 with themaster cylinder 24 will be described in detail. The caliper 22 can alsobe assembled with the hydraulic brake hose structure 14 in the samemanner described through reference to FIG. 11 for the master cylinder24. Thus, the detailed description of the steps of assembling of thecaliper 22 with the hydraulic brake hose structure 14 will be omittedfor the sake of brevity.

As seen in FIG. 11, the third sealing material 74 is removed or strippedfrom the first threaded fitting 54 to unseal the master cylinder 24illustrated in FIG. 10. In particular, the stripping tab 74 a is heldand pulled for removing the third sealing material 74 from the firstthreaded fitting 54. Then, the hydraulic brake hose structure 14illustrated in FIG. 3 is coupled to the master cylinder 24. Inparticular, the first end portion 50 a of the flexible tube 50 isinserted into the hose attachment bore 51 a such that the flexible tube50 extends through the first threaded fitting 54 and the first tubularbushing 58. In response to this insertion, the rupturing insert 63ruptures or punctures the first sealing material 62, which fluidlyconnects the interior passage 50 c of the flexible tube 50 to the firstfluid path of the master cylinder 24. The first end portion 50 a of theflexible tube 50 is inserted to the hose attachment bore 51 a until thefirst sealing material 62 is ruptured by the rupturing insert 63 and theflange section 56 a of the first tubular insert 56 is axially pushedagainst the annular flange section 63 b of the rupturing insert 63.Thus, the rupturing insert 63 is securely sandwiched between the firsttubular insert 56 and the annular inner end face of the internalthreaded bore 24 a of the master cylinder 24.

Furthermore, the first threaded fitting 54 is fastened with the finaltightening torque, which axially compresses the first tubular bushing58. As a result, the first tubular bushing 58 is deformed so as tosqueeze the first end portion 50 a of the flexible tube 50 onto thefirst tubular insert 56, thereby securely coupling the first end portion50 a of the flexible tube 50 to the hose attachment section 39 of themaster cylinder 24. As mentioned above, the second end portion 50 b ofthe flexible tube 50 can also be coupled to the hose attachment section46 of the caliper 22 in the same manner. As a result, the fluid path ofthe master cylinder 24 (e.g., a hydraulic component) is operativelycoupled to the fluid path of the caliper 22 (e.g., an additionalhydraulic component).

Referring to FIGS. 12 to 14, a protective or protection cap 92 (e.g., afirst protective cap) for protecting the seals (e.g., first and secondseal) of the hydraulic brake hose structure 14 will be described. Theprotective cap 92 is arranged to protect the first end portion 50 a thatis sealed by the first sealing material 62. Of course, the protectivecap 92 can also be used for the second end portion 50 b that is sealedby the second sealing material 72. Since the constructions of the firstand second end portions 50 a and 50 b are identical to each other, thedetailed description of the protective cap 92 used for the second endportion 50 b will be omitted for the sake of brevity.

As best seen in FIG. 13, the protective cap 92 is removably attached tothe first end portion 50 a such that the protective cap 92 accommodatesthe first end portion 50 a, the first tubular insert 56 and the firstsealing material 62 therein. The protective cap 92 is constructed of aresin material such as a plastic, or an elastic material such as arubber, such that the first end portion 50 a of the flexible tube 50,which is made of a rubber, is fittedly coupled to the protective cap 92.Of course, any suitable material can be utilized for the protective cap92 as needed and/or desired. The protective cap 92 has a convex orspherical head portion 92 a (e.g., a spherical head) and a bottomedcylindrical portion 92 b arranged with respect to the head portion 92 a.The head portion 92 a forms a distal end of the protective cap 92. Thehead portion 92 a has a traverse through hole 92 c (e.g., a throughhole) that radially extends through the head portion 92 a. As seen inFIG. 14, the through hole 92 c forms a cord attachment portion forattaching a ring cord or strap 94 to the protective cap 92. Thecylindrical portion 92 b defines a cylindrical inner face or bore 92 dwithin which the first end portion 50 a of the flexible tube 50 with thefirst sealing material 62 is disposed. The protective cap 92 isintegrally formed as a one-piece, unitary member.

As seen in FIG. 13, the hydraulic brake hose structure 14 is prefilledwith hydraulic fluid and sealed for shipment (see also FIG. 3). With theprotective cap 92, the first and second sealing materials 62 and 72 areprevented from being ruptured during shipment due to contacting withexternal objects, thereby preventing oil leakage from the hydraulicbrake hose structure 14 during shipment. Furthermore, with theprotective cap 92, the first and second sealing materials 62 and 72 areprevented from being ruptured during installation of the hydraulic brakehose structure 14 through an interior of a bicycle frame body (notshown). Specifically, while installing the hydraulic brake hosestructure 114 to the bicycle frame body, the first end portion 50 a (orthe second end portion 50 b) with the protective cap 92 is introducedinto the interior of the bicycle frame body via an entrance through-holeformed in the bicycle frame body. Then, the first end portion 50 a (orthe second end portion 50 b) with the protective cap 92 is guided alongan interior surface of the bicycle frame body. Since the protective cap92 has the convex or spherical head portion 92 a, the first end portion50 a (or the second end portion 50 b) with the protective cap 92 can besmoothly guided along the interior surface of the bicycle frame bodyduring the installation. Furthermore, with the protective cap 92, thefirst sealing material 62 (or the second sealing material 72) isprevented from being ruptured due to contacting interior objects withinthe bicycle frame body, thereby preventing oil leakage from thehydraulic brake hose structure 14 during the installation. Furthermore,the first end portion 50 a or the second end portion 50 b) with theprotective cap 92 exits from an exit through-hole formed in the bicycleframe body. Since the cord 94 is attached to the through hole 92 c ofthe protective cap 92, the first end portion 50 a (or the second endportion 50 b) with the protective cap 92 can be easily pulled out fromthe interior of the bicycle frame body through the exit through-hole ofthe bicycle frame body by hooking the cord 94 through the exitthrough-hole of the bicycle frame body with a hooking tool.

Referring to FIGS. 15 to 17, a lever stopper 98 (e.g., a lever retainingtool) for retaining a position of brake lever 28 relative to the brakehousing 23 will be described. The lever stopper 98 is removably arrangedrelative to the brake housing 23 and the brake lever 28 (e.g., anoperating lever) to prevent the brake lever 28 from moving relative tothe brake housing 23. Specifically, the lever stopper 98 is arrangedsuch that the brake lever 28 is prevented from moving from a restposition of the brake lever 28 toward a brake operating position of thebrake lever 28 during shipment of the brake operating mechanism 20.

As seen in FIG. 16, the brake lever 28 has a coupling portion 28 a, apush rod 28 b, a connecting member 28 c, and a pivot axle 28 d. Thebrake lever 28 is pivotally coupled to the brake housing 23 about thepivot axle 28 d. The connecting member 28 c is rotatable relative to thecoupling portion 28 a. The brake lever 28 is connected to the piston 34by coupling portion 28 a, the coupling the push rod 28 b and theconnecting member 28 c. Specifically, in response to gripping the brakelever 28, the coupling portion 28 a pivots about the pivot axle 28 d,which also pushes the push rod 28 b via the connecting member 28 c. Thepush rod 28 b is adjustably connected to the brake lever 28 by theconnecting member 28 c with a threaded hole. The push rod 28 b isthreaded into the threaded hole of the connecting member 28 c. One endof the push rod 28 b is provided with a socket for inserting anadjusting tool 99 therein, while the other end of the push rod 28 b isengaged with the piston 34. By rotating the push rod 28 b with theadjusting tool 99, the reach between the brake lever 28 and a handlebar30 (see FIG. 1) can be adjusted. When the brake lever 28 pivots from therest position towards the brake operating position, the push rod 28 bpushes the piston 34 to presses hydraulic fluid in the master cylinder24.

The lever stopper 98 has a rod shaped mounting part 98 a and a retainingpart 98 b with a pair of access windows 98 c. The lever stopper 98 isconstructed of a resin material such as a plastic. Of course, anysuitable rigid material can be utilized for the lever stopper 98 asneeded and/or desired. The lever stopper 98 is formed of a pin thatoperatively connects the brake housing 23 and the brake lever 28. Inparticular, the mounting part 98 a is dimensioned such that the mountingpart 98 a is fitted to the clamp 26. The retaining part 98 b extendsfrom the mounting part 98 a. The retaining part 98 b has a receivingsurface that receives the brake lever 28 while the mounting part 98 a iscoupled to the clamp 26, which restricts movement of the brake lever 28relative to the clamp 26 of the brake housing 23. In particular, whenthe lever stopper 98 is attached to the brake operating mechanism 20,the reach between the brake lever 28 and the clamp 26 can be adjusted byrotating the push rod 28 b through one of the access windows 98 c (leftside access window 98 c in FIG. 17) with the adjusting tool 99. Inparticular, the reach can be adjusted such that the brake lever 28contacts with the receiving surface of the retaining part 98 b while thebrake lever 28 is at the rest position. For example, the reach isadjusted to 90 mm. As a result, the lever stopper 98 prevents the brakelever 28 from moving relative to the brake housing 23 while the leverstopper 98 is attached to the brake operating mechanism 20.

As seen in FIG. 15, the brake operating mechanism 20 is prefilled withhydraulic fluid and sealed with the third sealing material 74 forshipment (see also FIG. 5). With the lever stopper 98, the third sealingmaterial 74 is prevented from being ruptured during shipment due tohydraulic pressure created in response to movement of the brake lever 28relative to the brake housing 23, thereby preventing oil leakage fromthe brake operating mechanism 20 during shipment.

As seen in FIGS. 15 to 17, the lever stopper 98 is attached to aright-hand side brake operating mechanism 20. On the other hand, thelever stopper 98 can also be attached to a left-hand side brakeoperating mechanism. Specifically, the lever stopper 98 is symmetricallyformed with respect to a center axis X of the retaining part 98 b. Whenthe lever stopper 98 is attached to the left-hand side brake operatingmechanism 20, the reach between the brake lever 28 and the clamp 26 canbe also adjusted by rotating the push rod 28 b through the other of theaccess windows 98 c (right side access window 98 c in FIG. 17) with theadjusting tool 99. As a result, the lever stopper 98 prevents the brakelever 28 from moving relative to the brake housing 23 while the leverstopper 98 is attached to the brake operating mechanism 20.

Referring to FIGS. 18 and 19, modified sealing materials (i.e., modifiedsealing materials or plugs 104 and 108) for sealing the hydraulic fluidretaining area 76 of the master cylinder 24 will be described. As seenin FIG. 5, the master cylinder 24 is prefilled with hydraulic fluid andsealed with the strippable third sealing material 74. On the other hand,the sealing of the master cylinder 24 can be performed in differentmanners as illustrated in FIGS. 18 and 19. In view of the similaritybetween the example illustrated in FIG. 5 and the modified examplesillustrated in FIGS. 18 and 19, the parts of the modified examples thatare identical to the parts of the illustrated example illustrated inFIG. 5 will be given the same reference numerals as the parts of theillustrated example illustrated in FIG. 5. Moreover, the descriptions ofthe parts of the modified examples that are identical to the parts ofthe illustrated example in FIG. 5 may be omitted for the sake ofbrevity. While, in FIGS. 18 and 19, the modified sealing plugs 104 and108 are illustrated as being coupled to the master cylinder 24, thesemodified sealing plugs 104 and 108 can also be used with the caliper 22.

As seen in FIG. 18, the master cylinder 24 is prefilled with hydraulicfluid and sealed at an end by the sealing material or plug 104 (e.g., afirst seal or a third seal). Specifically, the sealing plug 104 forms adetachable plug detachably coupled to a modified threaded fasteningsleeve or fitting 102, The sealing plug 104 has an enlarged head portion104 a, a flange portion 104 b, and a body portion 104 c extends betweenthe enlarged head portion 104 a and the flange portion 104 b. Thesealing plug 104 is fitted to an interior bore of the threaded fitting102. The sealing plug 104 is integrally formed as a one-piece, unitarymember. The sealing plug 104 is made of an elastic material, such asrubber. Of course, any suitable material can be utilized for the sealingplug 104 as needed and/or desired. The threaded fitting 102 is identicalto the first threaded fitting 54 illustrated in FIG. 5, excepting thatthe threaded fitting 102 has an annular recess 102 b on the interiorbore of the threaded fitting 102.

When providing the master cylinder 24 filled with hydraulic fluid, therupturing insert 63, the first tubular bushing 58 and the threadedfitting 102 are assembled to the master cylinder 24 in a mannerdescribed through reference to FIGS. 7 to 9. In particular, a threadedportion 102 a of the threaded fitting 102 is threaded to the internalthreaded bore 24 a of the master cylinder 24. Furthermore, the sealingplug 104 is fitted to the interior bore of the threaded fitting 102 suchthat the enlarged head portion 104 a is engaged with the annular recess102 b, which prevents an axial movement of the sealing plug 104. Thebody portion 104 c has a larger diameter than the interior bore of thethreaded fitting 102. Thus, when the sealing plug 104 is inserted intothe interior bore of the threaded fitting 102, the opening of thethreaded fitting 102 is radially sealed with the body portion 104 c ofthe sealing plug 104. The flange portion 104 b has a larger diameterthan an outer periphery of the threaded fitting 102. The sealing plug104 is inserted into the interior bore of the threaded fitting 102 untilthe flange portion 104 b contacts with an annular end face 102 c of thethreaded fitting 102. After the sealing plug 104 is coupled to thethreaded fitting 102, the hydraulic fluid retaining area 76 of themaster cylinder 24 is filled with hydraulic fluid.

Furthermore, when the master cylinder 24 is hydraulically connected tothe hydraulic brake hose structure 14 (see FIG. 2A), the sealing plug104 is removed from the threaded fitting 102, and the first end portion50 a of the flexible tube 50 is attached to the hose attachment section39 of the master cylinder 24 though the threaded fitting 102 and thefirst tubular bushing 58. The sealing plug 104 is removed from thethreaded fitting 102 by merely being pulled out from the threadedfitting 102. The flange portion 104 b can be held while removing thesealing plug 104 from the threaded fitting 102. Of course, the sealingplug 104 can be removed by a removal tool having constructions similarto corkscrews.

As seen in FIG. 19, the master cylinder 24 is prefilled with hydraulicfluid and sealed at an end by the sealing material or plug 108 (e.g., afirst seal or a third seal). Specifically, the sealing plug 108 forms adetachable plug detachably coupled to a modified threaded fasteningsleeve or fitting 106. The sealing plug 108 has a head portion 108 awith a socket hole 108 b, an engagement flange 108 c, and a flangeportion 108 d. The engagement flange 108 c is formed around a bodyportion 108 e extends between the head portion 108 a and the flangeportion 108 d. The sealing plug 108 is fitted to an interior bore of thethreaded fitting 106. The sealing plug 108 is integrally formed as aone-piece, unitary member. The sealing plug 108 is made of an elasticmaterial, such as rubber. Of course, any suitable material can beutilized for the sealing plug 108 as needed and/or desired. The threadedfitting 106 is identical to the first threaded fitting 54 illustrated inFIG. 5, excepting that the threaded fitting 106 has an annular recess106 b on the interior bore of the threaded fitting 106.

When providing the master cylinder 24 filled with hydraulic fluid, therupturing insert 63, the first tubular bushing 58 and the threadedfitting 106 are assembled to the master cylinder 24 in a mannerdescribed through reference to FIGS. 7 to 9. In particular, a threadedportion 106 a of the threaded fitting 106 is threaded to the internalthreaded bore 24 a of the master cylinder 24. Furthermore, the sealingplug 108 is fitted to the interior bore of the threaded fitting 106 suchthat the engagement flange 108 c is engaged with the annular recess 106b of the threaded fitting 106, which prevents an axial movement of thesealing plug 108. The body portion 108 e has a longer length than theaxial dimension between the annular end face 106 c of the threadedfitting 106 and the annular flange section 63 b of the rupturing insert63. Thus, when the engagement flange 108 c is engaged with the annularrecess 106 b, the head portion 108 a axially contacts with the annularflange section 63 b of the rupturing insert 63 such that the socket hole108 b of the head portion 108 a accommodates the end section 63 a of therupturing insert 63. Thus, the hydraulic fluid retaining area 76extending through the rupturing insert 63 is axially blocked with anaxial interface between the head portion 108 a of the sealing plug 108and the flange section 63 b of the rupturing insert 63. Furthermore,when the engagement flange 108 c is engaged with the annular recess 106b of the threaded fitting 106, the engagement flange 108 c is radiallydeformed by the annular recess 106 b. This creates a radial sealingbetween the interior bore of the threaded fitting 106 and the sealingplug 108. Furthermore, when the engagement flange 108 c is engaged withthe annular recess 106 b, the head portion 108 a axially contacts withthe annular flange section 63 b of the rupturing insert 63, which alsoradially deforms the body portion 1108 e of the sealing plug 108. As aresult, when the sealing plug 108 is inserted into the interior bore ofthe threaded fitting 106, the opening of the threaded fitting 106 isradially sealed with the body portion 108 e of the sealing plug 108.Accordingly, with the sealing plug 108, the hydraulic fluid retainingarea 76 of the master cylinder 24 is securely sealed. After the sealingplug 108 is coupled to the threaded fitting 106, the hydraulic fluidretaining area 76 of the master cylinder 24 is filled with hydraulicfluid.

Furthermore, when the master cylinder 24 is hydraulically connected tothe hydraulic brake hose structure 14 (see FIG. 2A), the sealing plug108 is removed from the threaded fitting 106, and the first end portion50 a of the flexible tube 50 is attached to the hose attachment section39 attic master cylinder 24 though the threaded fitting 106 and thefirst tubular bushing 58. The sealing plug 108 is removed from thethreaded fitting 106 by merely being pulled out from the threadedfitting 106. The flange portion 108 d can be held while removing thesealing plug 108 from the threaded fitting 102. Of course, the sealingplug 108 can be removed by a removal tool having constructions similarto corkscrews.

Referring to FIGS. 20 and 21, a modified hydraulic brake hose structurefor fluidly connecting the brake operating mechanism 20 and the caliper22 will be described. As seen in FIG. 1, the brake operating mechanism20 and the caliper 22 is hydraulically connected with a single hydraulicbrake hose structure 14 that is integrally formed as a one-piece member.On the other hand, the brake operating mechanism 20 and the caliper 22can be hydraulically connected in a different manner as illustrated inFIGS. 20 and 21. In view of the similarity between the exampleillustrated in FIG. 1 and the modified example illustrated in FIGS. 20and 21, the parts of the modified example that are identical to theparts of the illustrated example illustrated in FIG. 1 will be given thesame reference numerals as the parts of the illustrated exampleillustrated in FIG. 1. Moreover, the descriptions of the parts of themodified example that are identical to the parts of the illustratedexample in FIG. 1 may be omitted for the sake of brevity. While, inFIGS. 20 and 21, the modified hydraulic connection is illustrated asbeing used in the disc brake assembly 10, the modified hydraulicconnection can also be used in the front disc brake assembly.

As seen in FIG. 20, the brake operating mechanism 20 and the caliper 22are hydraulically connected to each other via a pair of first and secondhydraulic brake hose structures 114 and 115 that are coupled togetherwith a hydraulic hose coupler 116. The first and second hydraulic brakehose structures 114 and 115 are independently formed as separate membersand are hydraulically connected to each other with the hydraulic hosecoupler 116. The total lengths of the first and second hydraulic brakehose structures 114 and 115 are almost equal to the length of thehydraulic brake hose structure 14 illustrated in FIG. 1.

The first hydraulic brake hose structure 114 is hydraulically connectedto the brake operating mechanism 20. particular, one end of the firsthydraulic brake hose structure 114 is fixedly coupled to the mastercylinder 24 in a manner illustrated in FIG. 2A, or in a well knownconventional manner. The other end portion 114 a of the first hydraulicbrake hose structure 114 has an identical construction to the first andsecond end portions 50 a and 50 b of the hydraulic brake hose structure14 illustrated in FIGS. 3 and 4. Specifically, the end portion 114 a ofthe first hydraulic brake hose structure 114 is sealed with a sealingmaterial 114 b. The sealing material 114 b is formed of a thin flexiblesheet of metal foil. The sealing material 114 b is adhesively attachedto the end portion 114 a to seal an opening of the end portion 114 a ofthe first hydraulic brake hose structure 114. With this connection ofthe brake operating mechanism 20 and the first hydraulic brake hosestructure 114, these component forms a single hydraulic fluid path of asingle hydraulic component that continuously extends from the mastercylinder 24 (e.g., a hydraulic component body) to the first hydraulicbrake hose structure 114 (e.g., a hydraulic hose). The master cylinder24 is operatively joined with one end of the first hydraulic brake hosestructure 114. The end of this hydraulic path is defined by the endportion 114 a of the first hydraulic brake hose structure 114. Thissingle hydraulic fluid path of the hydraulic component (i.e., acombination of the brake operating mechanism 20 and the first hydraulicbrake hose structure 114) is sealed with the sealing material 114 b, andprefilled with hydraulic fluid. Thus, the brake operating mechanism 20and the first hydraulic brake hose structure 114 can be treated as asingle hydraulic component while shipping. In other words, the brakeoperating mechanism 20 and the first hydraulic brake hose structure 114form a hydraulic component having fluid path filled with hydraulicfluid. The sealing material 114 b forms a rupturable first seal arrangedto seal an end of the fluid path of the hydraulic component.

The second hydraulic brake hose structure 115 is hydraulically connectedto the caliper 22. In particular, one end of the second hydraulic brakehose structure 115 is fixedly coupled to the caliper 22 in a mannerillustrated in FIG. 2A, or in a well-known conventional manner. Theother end portion 115 a of the second hydraulic brake hose structure 115has an identical construction to the first and second end portions 50 aand 50 b of the hydraulic brake hose structure 14 illustrated in FIGS. 3and 4. Specifically, the end portion 115 a of the second hydraulic brakehose structure 115 is sealed with a sealing material 115 b. The sealingmaterial 115 b is formed of a thin flexible sheet of metal foil. Thesealing material 115 b is adhesively attached to the end portion 115 ato seal an opening of the end portion 115 a of the second hydraulicbrake hose structure 115. With this connection of the caliper 22 and thesecond hydraulic brake hose structure 115, these component forms asingle hydraulic fluid path of a single hydraulic component thatcontinuously extends from the caliper 22 (e.g., a hydraulic componentbody) to the second hydraulic brake hose structure 115 (e.g., ahydraulic hose). The caliper 22 is operatively joined with one end ofthe second hydraulic brake hose structure 115. The end of this hydraulicpath is defined by the end portion 115 a of the second hydraulic brakehose structure 115. This single hydraulic fluid path of the hydrauliccomponent (i.e., a combination of the caliper 22 and the secondhydraulic brake hose structure 115) is sealed with the sealing material115 b, and prefilled with hydraulic fluid. Thus, the caliper 22 and thesecond hydraulic brake hose structure 115 can be treated as a singlehydraulic component while shipping. In other words, the caliper 22 andthe second hydraulic brake hose structure 115 form a hydraulic componenthaving fluid path filled with hydraulic fluid. The sealing material 115b forms a rupturable first seal arranged to seal an end of the fluidpath of the hydraulic component.

The brake operating mechanism 20 and the caliper 22 are hydraulicallyconnected to each other via the hydraulic hose coupler 116.Specifically, the brake operating mechanism 20 and the caliper 22 arehydraulically connected to each other by hydraulically coupling thefirst and second hydraulic brake hose structures 114 and 115 to thehydraulic hose coupler 116, respectively. As illustrated in FIG. 21, thehydraulic hose coupler 116 has a coupler body with first and second hoseattachment sections 120 and 122 with first and second internal threadedbores 120 a and 122 a (e.g., first and second attachment bores),respectively. The first and second internal threaded bores 120 a and 122a is configured to fluidly communicate with respect to each other viafirst and second ports 120 b and 122 b. The hydraulic hose coupler 116further has first and second tubular rupturing inserts 124 and 125 thatare fittedly coupled to the first and second ports 120 b and 122 b,respectively. Specifically, the first and second rupturing inserts 124and 125 are disposed in the first and second internal threaded bores 120a and 122 a, respectively. The first and second rupturing inserts 124and 125 are arranged to puncture the sealing materials 114 b and 115 bof the first and second hydraulic brake hose structures 114 and 115,respectively, to fluidly communicate the first and second hydraulicbrake hose structures 114 and 115 relative to each other. The first andsecond rupturing inserts 124 and 125 are identical to the rupturinginsert 63 or the rupturing insert 73 (see FIG. 2A). Specifically, thefirst rupturing insert 124 has a tubular end section 124 a, an annularflange section 124 b, and a tubular body section 124 c. The secondrupturing insert 125 has a tubular end section 125 a, an annular flangesection 125 b, and a tubular body section 125 c.

The first hydraulic brake hose structure 114 is coupled to the firsthose attachment section 120 of the hydraulic hose coupler 116 with athreaded fastening sleeve or fitting 117 a and a tubular bushing 117 b.In particular, the threaded fitting 117 a is identical to the firstthreaded fitting 54 or the second threaded fitting 64 (see FIG. 2A). Thetubular bushing 117 b is identical to the first tubular bushing 58 orthe second tubular bushing 68 (see FIG. 2A). The threaded fitting 117 aand the tubular bushing 117 b overly the end portion 114 a of the firsthydraulic brake hose structure 114. Then, the end portion 114 a with thethreaded fitting 117 a and the tubular bushing 117 b is inserted intothe first hose attachment section 120 of the hydraulic hose coupler 116,which ruptures the sealing material 114 b with the end section 124 a ofthe first rupturing insert 124. Then, the threaded fitting 117 a isthreaded to the first internal threaded bore 120 a of the hydraulic hosecoupler 116, which axially compresses the tubular bushing 117 b. As aresult, the tubular bushing 117 b is deformed so as to squeeze the endportion 114 a onto a tubular insert attached to the end portion 114 a,thereby coupling the first hydraulic brake hose structure 114 to thefirst hose attachment section 120 of the hydraulic hose coupler 116.More specifically, the sealed hydraulic fluid path made of the mastercylinder 24 and the first hydraulic brake hose structure 114 is fluidlyconnected to a passageway that extends through the first rupturinginsert 124. Thus, the master cylinder 24 and the first hydraulic brakehose structure 114 form a first section defining a first fluid path. Thefirst rupturing insert 124 forms a first seal rupturing structuredisposed in the vicinity of the first fluid path. The first rupturinginsert 124 physically ruptures the sealing material 114 b (e.g., a firstseal) of the first hydraulic brake hose structure 114 (e.g., a firsthydraulic hose).

Furthermore, the second hydraulic brake hose structure 115 is coupled tothe second hose attachment section 122 of the hydraulic hose coupler 116with a threaded fastening sleeve or fitting 118 a and a tubular bushing118 b. In particular, the threaded fitting 118 a is identical to thefirst threaded fitting 54 or the second threaded fitting 64 (see FIG.2A). The tubular bushing 118 b is identical to the first tubular bushing58 or the second tubular bushing 68 (see FIG. 2A). The threaded fitting118 a and the tubular bushing 118 b overly the end portion 115 a of thesecond hydraulic brake hose structure 115. Then, the end portion 115 awith the threaded fitting 118 a and the tubular bushing 118 b isinserted into the second hose attachment section 122 of the hydraulichose coupler 116, which ruptures the sealing material 115 b with the endsection 125 a of the second rupturing insert 125. Then, the threadedfitting 118 a. is threaded to the second internal threaded bore 122 a ofthe hydraulic hose coupler 116, which axially compresses the tubularbushing 118 b. As a result, the tubular bushing 118 b is deformed so asto squeeze the end portion 115 a onto a tubular insert attached to theend portion 115 a, thereby coupling the second hydraulic brake hosestructure 115 to the second hose attachment section 122 of the hydraulichose coupler 116. More specifically, the sealed hydraulic fluid pathmade of the caliper 22 and the second hydraulic brake hose structure 115is fluidly connected to a passageway that extends through the secondrupturing insert 125. Thus, the caliper 22 and the second hydraulicbrake hose structure 115 form a second section defining a second fluidpath. The second rupturing insert 125 forms a second seal rupturingstructure disposed in the vicinity of the second fluid path. The secondrupturing insert 125 physically ruptures the sealing material 115 b(e.g., a second seal) of the second hydraulic brake hose structure 115(e.g., a second hydraulic hose).

As a result, the brake operating mechanism 20 and the caliper 22 arehydraulically connected to each other via the first and second hydraulicbrake hose structures 114 and 115 that are hydraulically coupledtogether with the hydraulic hose coupler 116. In particular, the brakeoperating mechanism 20 with the first hydraulic brake hose structure 114(e.g., a hydraulic component) is operatively connected to the caliper 22with the second hydraulic brake hose structure 115 (e.g., an additionalhydraulic component). With this arrangement, the hydraulic hose coupler116 can be disposed within an interior of a bicycle frame body when thefirst and second hydraulic brake hose structures 114 and 115 extendswithin the interior of the bicycle frame body.

Furthermore, the hydraulic hose coupler 116 can be prefilled withhydraulic fluid prior to connecting the first and second hydraulic brakehose structures 114 and 115 to the hydraulic hose coupler 116. In thiscase, prior to coupling the first hydraulic brake hose structure 114 tothe first hose attachment section 120 of the hydraulic hose coupler 116,the threaded fitting 117 a and the tubular bushing 117 b are fastened tothe first hose attachment section 120 of the hydraulic hose coupler 116in a manner described with reference to FIGS. 8 and 9. Furthermore, anannular end face of the threaded fitting 117 a is sealed with a sealingmaterial in a manner described with reference to FIG. 10. Furthermore,prior to coupling the second hydraulic brake hose structure 115 to thesecond hose attachment section 122 of the hydraulic hose coupler 116,the threaded fitting 118 a and the tubular bushing 118 b are fastened tothe second hose attachment section 122 of the hydraulic hose coupler 116in a manner described with reference to FIGS. 8 and 9. Furthermore, ahydraulic fluid retaining area of the hydraulic hose coupler 116 definedby the first and second internal threaded bores 120 a and 122 a and thepassageways that extend through the first and second rupturing inserts124 and 125 is filled with hydraulic fluid. Then, an annular end face ofthe threaded fitting 118 a is sealed with a sealing material in a mannerdescribed with reference to FIG. 10.

With this prefilled hydraulic hose coupler 116, when the first hydraulicbrake hose structure 114 is coupled to the hydraulic hose coupler 116,the sealing material attached to the threaded fitting 117 a is removed,and the end portion 114 a of the first hydraulic brake hose structure114 is inserted through the threaded fitting 117 a and the tubularbushing 117 b, which ruptures the sealing material 114 b of the firsthydraulic brake hose structure 114 with the first rupturing insert 124.As a result, the first hydraulic brake hose structure 114 and the mastercylinder 24 are hydraulically connected to the hydraulic fluid retainingarea of the hydraulic hose coupler 116. Furthermore, when the secondhydraulic brake hose structure 115 is coupled to the hydraulic hosecoupler 116, the sealing material attached to the threaded fitting 118 ais removed, and the end portion 115 a of the second hydraulic brake hosestructure 115 is inserted through the threaded fitting 118 a and thetubular bushing 118 b, which ruptures the sealing material 115 b of thesecond hydraulic brake hose structure 115 with the second rupturinginsert 125. As a result, the second hydraulic brake hose structure 115and the caliper 22 are hydraulically connected to the hydraulic fluidretaining area of the hydraulic hose coupler 116, which also connectsthe master cylinder 24 and the caliper 22 relative to each other.

As seen in FIG. 20, the first and second hydraulic brake hose structures114 and 115 are hydraulically connected to each other with the hydraulichose coupler 116. On the other hand, the hydraulic component formed ofthe brake operating mechanism 20 and the first hydraulic brake hosestructure 114 illustrated in FIG. 20 can be directly coupled to thecaliper 22 (e.g., an additional hydraulic component). In particular, theend portion 114 a of the first hydraulic brake hose structure 114 can bedirectly coupled to the hose attachment section 46 of the caliper 22,and the sealing material 114 b of the first hydraulic brake hosestructure 114 is physically ruptured by the rupturing insert 73 of thecaliper 22. In this case, the first hydraulic brake hose structure 114has a length that is equal to the hydraulic brake hose structure 14illustrated in FIG. 3, and the caliper 22 has the constructionsillustrated in FIG. 6. Alternatively, the hydraulic component formed ofthe caliper 22 and the second hydraulic brake hose structure 115illustrated in FIG. 20 can be directly coupled to the brake operatingmechanism 20 (e.g., an additional hydraulic component). In particular,the end portion 115 a of the second hydraulic brake hose structure 115can be directly coupled to the hose attachment section 39 of the mastercylinder 24, and the seating material 115 b of the second hydraulicbrake hose structure 115 is physically ruptured by the rupturing insert63 of the master cylinder 24. in this case, the second hydraulic brakehose structure 115 has a length that is equal to the hydraulic brakehose structure 14 illustrated in FIG. 3, and the master cylinder 24 ofthe brake operating mechanism 20 has the constructions illustrated inFIG. 5.

Referring to FIG. 22, a modified protective or protection cap 130 (e.g.,a first protective cap) for protecting the seals (e.g., first and secondseal) of the hydraulic brake hose structure 14 will be described. Theprotective cap 130 has a hooked head portion 130 a (e.g., a hookportion) with a convex or spherical outer surface and a bottomedcylindrical portion 130 b arranged with respect to the hooked headportion 130 a. The protective cap 130 is identical to the protective cap92 illustrated in FIGS. 12 to 14, except for the construction of thehooked head portion 130 a. The protective cap 130 is arranged to protectthe first end portion 50 a that is sealed by the first sealing material62. Of course, the protective cap 130 can also be used for the secondend portion 50 b that is sealed by the second sealing material 72. Sincethe constructions of the first and second end portions 50 a and 50 b areidentical to each other, the detailed description of the protective cap130 used for the second end portion 50 b will be omitted for the sake ofbrevity.

The protective cap 130 is removably attached to the first end portion 50a such that the protective cap 130 accommodates the first end portion 50a, the first tubular insert 56 and the first sealing material 62therein. The protective cap 130 is constructed of a resin material suchas a plastic, or an elastic material such as a rubber, such that thefirst end portion 50 a of the flexible tube 50, which is made of arubber, is fittedly coupled to the protective cap 130. Of course, anysuitable material can be utilized for the protective cap 130 as neededand/or desired. The hooked head portion 130 a forms a distal end of theprotective cap 130. The hooked head portion 130 a has a traverse throughopening 130 c that radially extends through the hooked head portion 130a, The cylindrical portion 130 b defines a cylindrical inner face orbore 130 d within which the first end portion 50 a of the flexible tube50 with the first sealing material 62 is disposed. The protective cap130 is integrally formed as a one-piece, unitary member.

As seen in FIG. 3, the hydraulic brake hose structure 14 is prefilledwith hydraulic fluid and sealed for shipment. With the protective cap130, the first and second sealing materials 62 and 72 is prevented frombeing ruptured during shipment due to contacting with external objects,thereby preventing oil leakage from the hydraulic brake hose structure14 during shipment. Furthermore, with the protective cap 130, the firstand second sealing materials 62 and 72 are prevented from being rupturedduring installation of the hydraulic brake hose structure 14 through aninterior of a bicycle frame body (not shown). Specifically, whileinstalling the hydraulic brake hose structure 14 to the bicycle framebody, the first end portion 50 a (or the second end portion 50 b) withthe protective cap 130 is introduced into the interior of the bicycleframe body via an entrance through-hole formed in the bicycle framebody. Then, the first end portion 50 a (or the second end portion 50 b)with the protective cap 130 is guided along an interior surface of thebicycle frame body. Since the hooked head portion 130 a of theprotective cap 130 has the convex or spherical outer surface, the firstend portion 50 a (or the second end portion 50 b) with the protectivecap 130 can be smoothly guided along the interior surface of the bicycleframe body during the installation. Furthermore, with the protective cap130, the first scaling material 62 (or the second scaling material 72)is prevented from being ruptured due to contacting interior objectswithin the bicycle frame body, thereby preventing oil leakage from thehydraulic brake hose structure 14 during the installation. Furthermore,the first end portion 50 a (or the second end portion 50 b) with theprotective cap 130 exits from an exit through-hole formed in the bicycleframe body. Since the protective cap 130 has the hooked head portion 130a, the first end portion 50 a (or the second end portion 50 b) with theprotective cap 130 can be easily pulled out from the interior of thebicycle frame body through the exit through-hole of the bicycle framebody by hooking the hooked head portion 130 a with a hooking tool, suchas a ring cord.

Referring to FIGS. 23 to 27, a wedge-type lever stopper 132 (e.g., alever retaining tool) for retaining a position of the brake lever 28relative to the brake housing 23 will be described. The lever stopper 98described through reference to FIGS. 15 to 17 is operatively disposedbetween the brake lever 28 and the clamp 26. On the other hand, thelever stopper 132 is removably arranged relative to the master cylinder24 and the brake lever 28 (e.g., an operating lever) to prevent thebrake lever 28 from moving relative to the brake housing 23.Specifically, the lever stopper 132 is arranged such that the brakelever 28 is prevented from moving from a rest position of the brakelever 28 toward a brake operating position of the brake lever 28 duringshipment of the brake operating mechanism 20. The construction of thebrake lever 28 is described above through reference to FIG. 16. Thus,the detailed description of the brake lever 28 will be omitted for thesake of brevity.

The lever stopper 132 has a stopper body 134 and a pair of wedge legs136 that extends from the stopper body 134. The stopper body 134 and thewedge legs 136 are integrally formed as a one-piece, unitary member. Thelever stopper 132 is constructed of a resin material such as plastic, oran elastic material such as rubber. Of course, any suitable material canbe utilized for the lever stopper 132 as needed and/or desired. Thelever stopper 132 is formed of a wedge. The lever stopper 132 is drivenin the vicinity of the pivot axle 28 d of the brake lever 28, and in thevicinity of the piston 34. In particular, the lever stopper 132 issandwiched between a contact end face 24 b of the master cylinder 24 andan outer periphery 28 e of the coupling portion 28 a of the brake lever28 while the lever stopper 132 is attached to the brake operatingmechanism 20, More specifically, the lever stopper 132 has a cylindercontact surface 132 a on one side of the lever stopper 132, and a levercontact surface 132 b on the opposite side of the lever stopper 132. Thecylinder contact surface 132 a contacts with the contact end face 24 bof the master cylinder 24, while the lever contact surface 132 bcontacts with the outer periphery 28 e of the brake lever 28.Specifically, the lever contact surface 132 b further has a pair ofcontact sections 136 a on the wedge legs 136, respectively. The contactsections 136 a have an outer profile that corresponds to the outerperiphery 28 e of the coupling portion 28 a. The wedge legs 136 have athickness that decreases as approaching towards distal ends of the wedgelegs 136, respectively. More specifically, the wedge legs 136 isdimensioned such that the wedge legs 136 have a thickness thatcorresponding to the distance between the contact end face 24 b of themaster cylinder 24 and the outer periphery 28 e of the brake lever 28while the brake lever 28 is located at the rest position. The wedge legs136 are spaced apart from each other.

As seen in FIGS. 26 and 27, the lever stopper 132 is inserted through anaccess window 23 a of the brake housing 23 such that the push rod 28 bis disposed between the wedge legs 136. Then, the lever stopper 132 ispressed until a pair of latching bulges 136 b formed on inner opposingfaces of the wedge legs 136, respectively, are engaged with the push rod28 b, thereby preventing the lever stopper 132 from accidentally comingoff the brake operating mechanism 20. Furthermore, in this state, thelever stopper 132 is fittedly wedged between the contact end face 24 bof the master cylinder 24 and the outer periphery 28 e of the couplingportion 28 a of the brake lever 28, which restricts pivotal movement ofthe coupling portion 28 a of the brake lever 28 about the pivot axle 28d relative to the master cylinder 24. In particular, when the leverstopper 132 is attached to the brake operating mechanism 20, the reachbetween the brake lever 28 and the clamp 26 can be adjusted by rotatingthe push rod 28 b with the adjusting tool 99 (see FIG. 16). inparticular, the reach can be adjusted such that the lever stopper 132 isfittedly wedged between the contact end face 24 b of the master cylinder24 and the outer periphery 28 e of the coupling portion 28 a of thebrake lever 28 while the brake lever 28 is at the rest position, As aresult, the lever stopper 132 prevents the brake lever 28 from movingrelative to the brake housing 23 while the lever stopper 132 is attachedto the brake operating mechanism 20.

As seen in FIG. 5, the brake operating mechanism 20 is prefilled withhydraulic fluid and sealed with the third sealing material 74 forshipment. With the lever stopper 132, the third sealing material 74 isprevented from being ruptured during shipment due to hydraulic pressurecreated in response to movement of the brake lever 28 relative to thebrake housing 23, thereby preventing oil leakage from the brakeoperating mechanism 20 during shipment.

As seen in FIG. 23, the lever stopper 132 is attached to a right-handside brake operating mechanism 20. On the other hand, the lever stopper132 can also be attached to a left-hand side brake operating mechanismin a manner described above.

Referring to FIGS. 28 to 30, a modified wedge-type lever stopper 152(e.g., a lever retaining tool) will be described. The lever stopper 132described through reference to FIGS. 23 to 27 is removably arrangedrelative to the master cylinder 24 and the brake lever 28. On the otherhand, the lever stopper 152 is used with a different type of brakeoperating mechanisms different from the brake operating mechanism 20 ina different manner. Specifically, the lever stopper 152 is used with abrake operating mechanism 140. The brake operating mechanism 140 is usedin the hydraulic brake system 12 illustrated in FIG. 1, instead of thebrake operating mechanism 20.

As best seen in FIG. 28, the brake operating mechanism 140 basicallyincludes a brake housing 142 with a master cylinder 144, a brake lever146, and a clamp 148. The master cylinder 144 is prefilled withhydraulic fluid and sealed with a sealing material 145 in a similarmanner to the brake operating mechanism 20. In particular, the sealingmaterial 145 is identical to the third sealing material 74 illustratedin FIG. 16, except that the sealing material 145 is attached to themaster cylinder 144. The brake lever 146 is pivotally coupled to thebrake housing 142 for creating hydraulic pressure in the master cylinder144. The clamp 148 is integrally formed with the brake housing 142 forsupporting the brake operating mechanism 140 relative to the handlebar30 (see FIG. 1) in a conventional manner. The constructions of the brakeoperating mechanism 140 can be identical to the constructions of thebrake operating mechanism 20 unless otherwise described hereafter. Thus,the details of each of the constructions of the brake operatingmechanism 140 will be omitted for the sake of brevity, except for theconstructions related to an attachment of the lever stopper 152.

As best seen in FIG. 29, the brake lever 146 has a cam protrusion 146 awith a cam surface 146 b. The brake lever 146 is pivotally attached tothe brake housing 142 for pivotal movement about a pivot pin 146 c. Themaster cylinder 144 is provided with a push rod assembly 150 forreciprocally sliding a piston (not shown) within the master cylinder144. The push rod assembly 150 has a push rod 150 a, a tubular camroller 150 b, and a push rod attachment member 150 c. The push rod 150 ais fixedly coupled to the push rod attachment member 150 c. The camroller 150 b is rotatably attached to the push rod attachment member 150c about a roller axle 150 d. The cam surface 146 b of the cam protrusion146 a directly contacts with the cam roller 150 b while the brake lever146 is in a rest position. As the brake lever 146 is moved from the restposition of the brake lever 146 toward a brake operating position of thebrake lever 146, the cam protrusion 146 a pivots about the pivot pin 146c towards an attachment surface 142 a of the brake housing 142, whichcauses the cam roller 150 b to rotate and ride along the cam surface 146b. As a result, the cam protrusion 146 a of the brake lever 146 pushesthe piston via the push rod assembly 150 to create hydraulic pressure inthe master cylinder 144. In other words, the brake lever 146 isoperatively coupled to the piston for moving the piston between a pistonrest position and a piston operating position.

The lever stopper 152 is used with the brake operating mechanism 140 forretaining a position of the brake lever 146 of the brake operatingmechanism 140 relative to the brake housing 142. Specifically, the leverstopper 152 is removably arranged relative to the brake housing 142 andthe brake lever 146 (e.g., an operating lever) to prevent the brakelever 146 from moving relative to the brake housing 142. Morespecifically, the lever stopper 152 is arranged such that the brakelever 146 is prevented from moving from the rest position of the brakelever 146 toward the brake operating position of the brake lever 146during shipment of the brake operating mechanism 140.

The lever stopper 152 is integrally formed as a one-piece, unitarymember. The lever stopper 152 is constructed of a resin material such asa plastic, or an elastic material such as rubber. Of course, anysuitable material can be utilized for the lever stopper 152 as neededand/or desired. The lever stopper 152 is formed of a wedge. The leverstopper 152 is driven in the vicinity of the pivot pin 146 c of thebrake lever 146, and in the vicinity of the piston. In particular, thelever stopper 152 is sandwiched or wedged between the attachment surface142 a of the brake housing 142 and the cam protrusion 146 a of the brakelever 146 while the lever stopper 152 is attached to the brake operatingmechanism 140. The lever stopper 152 has a roller receiving portion 154,a stopper body 156 and an engagement protrusion 158. In particular, asseen in FIG. 29, the roller receiving portion 154 is fittedly disposedbetween the cam roller 150 b and the attachment surface 142 a of thebrake housing 142. The roller receiving portion 154 has a semi-circularcontact surface 154 a that corresponds to an outer periphery of the camroller 150 b and contacts with the outer periphery of the cam roller 150b. The roller receiving portion 154 is formed on the stopper body 156.The stopper body 156 is fittedly disposed between the brake housing 142and the brake lever 146. In particular, the stopper body 156 is fittedlydisposed between the attachment surface 142 a of the brake housing 142and a distal end of the cam protrusion 146 a of the brake lever 146.Specifically, the stopper body 156 has a lower contact surface 156 a andan upper contact surface 156 b. The lower contact surface 156 a contactswith the attachment surface 142 a of the brake housing 142, while theupper contact surface 156 b contacts with the distal end of the camprotrusion 146 a of the brake lever 146. The stopper body 156 has athickness between the lower and upper contact surfaces 156 a and 156 bthat corresponds to the distance between the attachment surface 142 a ofthe brake housing 142 and the distal end of the cam protrusion 146 a ofthe brake lever 146 when the brake lever 146 is at the rest position.The stopper body 156 further has a traverse engagement rib 156 c formedon the upper contact surface 156 b. The engagement rib 156 c is engagedwith the distal end of the cam protrusion 146 a of the brake lever 146such that the engagement rib 156 c prevents the distal end of the camprotrusion 146 a from being disengaged with the upper contact surface156 b of the stopper body 156 and wedged between the contact surface 154a of the roller receiving portion 154 and the outer periphery of the camroller 150 b. The engagement protrusion 158 is formed on the stopperbody 156. The engagement protrusion 158 is disposed between the outerperiphery of the cam roller 150 h of the push rod assembly 150 and thepush rod attachment member 150 c of the push rod assembly 150. Theengagement protrusion 158 is engaged with the outer periphery of the camroller 150 b of the push rod assembly 150 and the push rod attachmentmember 150 c of the push rod assembly 150, which prevents the leverstopper 152 from moving with respect to the push rod assembly 150.

As seen in FIG. 29, the lever stopper 152 is pushed and wedged into thegap between the attachment surface 142 a of the brake housing 142 andthe cam roller 150 b of the push rod assembly 150 until the engagementprotrusion 158 rides over the cam roller 150 b. Specifically, in thisstate, the engagement protrusion 158 is disposed between the cam roller150 b and the push rod attachment member 150 c. Furthermore, the rollerreceiving portion 154 is disposed between the cam roller 150 b and theattachment surface 142 a of the brake housing 142. Thus, the leverstopper 152 is prevented from accidentally coming off the brakeoperating mechanism 140. Furthermore, in this state, the lever stopper152 is fittedly wedged between the attachment surface 142 a of the brakehousing 142 and the distal end of the cam protrusion 146 a of the brakelever 146, which restricts pivotal movement of the cam protrusion 146 aof the brake lever 146 about the pivot pin 146 c relative to the brakehousing 142. In particular, when the lever stopper 152 is attached tothe brake operating mechanism 140, the reach between the brake lever 146and the clamp 148 can be adjusted by rotating an adjusting knob 149 (seeFIG. 28). In particular, the reach can be adjusted such that the leverstopper 152 is fittedly wedged between the attachment surface 142 a ofthe brake housing 142 and the distal end of the cam protrusion 146 a ofthe brake lever 146 while the brake lever 146 is at the rest position.As a result, the lever stopper 152 prevents the brake lever 146 frommoving relative to the brake housing 142 while the lever stopper 152 isattached to the brake operating mechanism 140. Moreover, even if agripping force is accidentally excreted on the brake lever 146, the camprotrusion 146 a presses the stopper body 156 such that the lowercontact surface 156 a of the stopper body 156 is pressed against theattachment surface 142 a of the brake housing 142, which in turnincreases friction between the lower contact surface 156 a of thestopper body 156 and the attachment surface 142 a of the brake housing142. As a result, the lever stopper 152 is further prevented from movingalong the brake housing 142. Since the cam roller 150 b are engaged withthe roller receiving portion 154, the push rod assembly 150 does notmove relative to the lever stopper 152. Accordingly, hydraulic pressureis further prevented from being created in the master cylinder 144 evenif a gripping force is accidentally excreted on the brake lever 146.

As seen in FIG. 28, the brake operating mechanism 140 is prefilled withhydraulic fluid and sealed with the sealing material 145 for shipment.With the lever stopper 152, the sealing material 145 is prevented frombeing ruptured during shipment due to hydraulic pressure created inresponse to movement of the brake lever 146 relative to the brakehousing 142, thereby preventing oil leakage from the brake operatingmechanism 140 during shipment.

As seen in FIGS. 28 and 29, the lever stopper 152 is attached to aright-hand side brake operating mechanism 140. On the other hand, thelever stopper 152 can also be attached to a left-hand side brakeoperating mechanism in a manner described above.

Referring to FIGS. 31 and 32, modified sealing materials (i.e., asealing material 162 and a sealing material or plug 168) for sealing theopening (e.g., a first opening) of the first end portion 50 a of theflexible tube 50 will be described. In other words, the sealing material162 and the sealing plug 168 forma first detachable seal arranged toseal the first opening of the first end of the hydraulic hose. As seenin FIG. 3, the hydraulic brake hose structure 14 is prefilled withhydraulic fluid and sealed with the rupturable sealing materials (i.e.,first and second sealing materials 62 and 72) that are ruptured inresponse to attachment of the hydraulic brake hose structure to themaster cylinder 24 and the caliper 22, respectively. On the other hand,the sealing material 162 and the sealing plug 168 are removably attachedto the first end portion 50 a of the flexible tube 50. Of course, thesealing material 162 and the sealing plug 168 can be removably attachedto the second end portion 50 b of the flexible tube 50.

As seen in FIG. 31, the sealing material 162 seals an end opening of theflexible tube 50. Specifically, the sealing material 162 is formed of athin flexible sheet of metal foil. The sealing material 162 is removablyor strippably attached to an annular end face of the first tubularinsert 56 to overlie the opening of the flexible tube 50 that is definedby the annular end face of the first tubular insert 56. in other words,the sealing material 162 forms a strippable sheet. The sealing material162 is thermally bonded to the first tubular insert 56. The sealingmaterial 162 has a stripping tab 162 a that is held for removing thesealing material 162 from the first tubular insert 56. The stripping tab162 a extends outward relative to an outer periphery of the firsttubular insert 56.

When the flexible tube 50 with the sealing material 162 is hydraulicallyconnected to the master cylinder 24 (see FIG. 2A), the sealing material162 is first removed or detached from the flexible tube 50 by pullingthe stripping tab 162 a. Then, the first end portion 50 a is insertedinto the hose attachment section 39 (see FIG. 2A) of the master cylinder24. in this case, the master cylinder 24 does not need to have therupturing insert 63 for rupturing a seal. Furthermore, the sealingmaterial 162 can be used with the first and second hydraulic brake hosestructures 114 and 115. In particular, the sealing material 162 can bedetachably attached to the end portions 114 a and 115 a instead of thesealing material 114 b and 115 b, respectively.

As seen in FIG. 32, the sealing plug 168 seals an end opening of theflexible tube 50. Specifically, the sealing plug 168 is formed of adetachable plug. The sealing plug 168 is made of an elastic material,such as rubber. Of course, any suitable material can be utilized for thesealing plug 168 as needed and/or desired. The sealing plug 168 isintegrally formed as a one-piece, unitary member. The sealing plug 168is removably or detachably attached to a tubular insert 166 to overliethe opening of the flexible tube 50 that is defined by the annular endface of the tubular insert 166. The tubular insert 166 is identical tothe first tubular insert 56, except for an annular recess 166 a beingformed on an interior bore 166 b of the tubular insert 166. The sealingplug 168 is pressed into the interior bore 166 b of the tubular insert166.

The sealing plug 168 has an enlarged head portion 168 a, a flangeportion 168 b, and a body portion 168 c extends between the enlargedhead portion 168 a and the flange portion 168 b. The sealing plug 168 isfitted to or plugged into the interior bore 166 b of the tubular insert166. Specifically, the sealing plug 168 is fitted to the interior bore166 b of the tubular insert 166 such that the enlarged head portion 168a is engaged with the annular recess 166 a, which prevents an axialmovement of the sealing plug 168. The body portion 168 c has a largerdiameter than the interior bore 166 b of the tubular insert 166. Thus,when the sealing plug 168 is inserted into the interior bore 166 b ofthe tubular insert 166, the opening of the tubular insert 166 isradially sealed with the body portion 168 c of the sealing plug 168. Theflange portion 168 b has a larger diameter than an outer periphery ofthe tubular insert 166. The sealing plug 168 is inserted into theinterior bore 166 b of the tubular insert 166 until the flange portion168 b contacts with an annular end face 166 c of the tubular insert 166,After the sealing plug 168 is coupled to tubular insert 166, theflexible tube 50 is filled with hydraulic fluid.

When the flexible tube 50 with the sealing plug 168 is hydraulicallyconnected to the master cylinder 24 (see FIG. 2A), the sealing plug 168is first removed or detached from the flexible tube 50 by holding theflange portion 168 b and pulling the flange portion 168 b. Of course,the sealing plug 168 can be removed by a removal tool havingconstructions similar to corkscrews. Then, the first end portion 50 a isinserted into the hose attachment section 39 (see FIG. 2A) of the mastercylinder 24. In this case, the master cylinder 24 does not need to havethe rupturing insert 63 for rupturing a seal. Furthermore, the sealingplug 168 can be used with the first and second hydraulic brake hosestructures 114 and 115. In particular, the sealing plug 168 can bedetachably attached to the end portions 114 a and 115 a instead of thesealing material 114 b and 115 b, respectively.

Referring to FIG. 33, a rupturing or puncturing tool 170 (e.g., arupturing member) for physically rupturing the first sealing material 62attached to the first end portion 50 a of the hydraulic brake hosestructure 14 will be described. Of course, the rupturing tool 170 can beutilized for physically rupturing the second sealing material 72attached to the second end portion 50 b (see FIG. 3) of the hydraulicbrake hose structure 14. However, since the constructions of the firstand second end portions 50 a and 50 b are identical to each other, thedetailed description of the rupturing tool 170 used for the second endportion 50 b will be omitted for the sake of brevity. In the illustratedembodiment illustrated through reference to FIG. 1, the hydraulic brakehose structure 14 is prefilled with hydraulic fluid and sealed with therupturable sealing materials (i.e., first and second sealing materials62 and 72) that are ruptured in response to attachment of the hydraulicbrake hose structure 14 to the master cylinder 24 and the caliper 22,respectively. On the other hand, with the rupturing tool 170, thesealing materials (i.e., first and second sealing materials 62 and 72)can be physically ruptured before the hydraulic brake hose structure 14is coupled to the master cylinder 24 and the caliper 22. In other words,with the rupturing tool 170, the first sealing material 62 is physicallyruptured in advance.

In particular, the rupturing tool 170 is independently provided from thebrake operating mechanism 20, the caliper 22, and the hydraulic brakehose structure 14, and can form a part of the hydraulic brake kit. Asseen in FIG. 33, the rupturing tool 170 is basically a tubular memberhaving a tubular end section 172. The end section 172 is formed as aneedle for rupturing or puncturing the first sealing material 62 of thehydraulic brake hose structure 14. In particular, the end section 172has a beveled distal end that punctures the first sealing material 62.The end section 172 of the rupturing tool 170 is inserted into thepassageway 56 c of the first tubular insert 56, which extends throughthe flange section 56 a and the tubular section 56 b, for rupturing thefirst sealing material 62 before the hydraulic brake hose structure 14is coupled to the brake operating mechanism 20. In other words, with therupturing tool 170, the first sealing material 62 is physically rupturedin advance. The end section 172 is dimensioned such that the end section172 is fittedly inserted into the passageway 56 c of the first tubularinsert 56.

The rupturing tool 170 is constructed of a resin material such as aplastic. Of course, any suitable rigid material can be utilized for therupturing tool 170 as needed and/or desired. As seen in FIG. 33, therupturing tool 170 is basically a tubular member. However, any suitableconstruction can be utilized for the rupturing tool 170 as needed and/ordesired. Specifically, the rupturing tool 170 can be a solid member.

Furthermore, the rupturing tool 170 can also be utilized for physicallyrupturing the third sealing material 74 (see FIG. 5) when or before thebrake operating mechanism 20 is coupled to the first end portion 50 a ofthe hydraulic brake hose structure 14. The rupturing tool 170 can alsobe utilized for physically rupturing the fourth sealing material 84 (seeFIG. 6) when or before the caliper 22 is coupled to the second endportion 50 b of the hydraulic brake hose structure 14. Furthermore, therupturing tool 170 can also be utilized for physically rupturing thesealing materials 114 b and 115 b of the first and second hydraulicbrake hose structures 114 and 115 (FIG. 20) when or before the first andsecond hydraulic brake hose structures 114 and 115 are coupled to thehydraulic hose coupler 116.

In the illustrated embodiment, the hydraulic brake hose structure 14forms a hydraulic bicycle hose structure of the present disclosure.However, the construction of the hydraulic brake hose structure 14 canalso be applied to hydraulic bicycle hose structures for hydraulicallyconnecting hydraulic shifting systems, or other hydraulic bicyclesystems. Furthermore, the brake operating mechanism 20 and the caliper22 form hydraulic bicycle components of the present disclosure. However,the construction of the brake operating mechanism 20 and the caliper 22for rupturing seals of hydraulic connections can also be applied tohydraulic bicycle components used with a hydraulic shifting system, ahydraulic suspension adjusting system or other hydraulic bicyclesystems.

Referring to FIGS. 34 and 35, a hydraulic bicycle component (i.e.,hydraulic operating mechanism 220) used with a hydraulic bicycle system210 (e.g., a hydraulic shifting system, a hydraulic suspension adjustingsystem, and so force) will be described. As seen in FIG. 34, thehydraulic operating mechanism 220 is illustrated in the form of ahydraulic derailleur operating (actuation) device (e.g., a shiftoperation device) or a hydraulic suspension adjusting device (e.g., asuspension control operation device). Since the construction of thehydraulic derailleur operating device or the hydraulic suspensionadjusting device is well known (e.g., see U.S. Pat. Nos. 7,509,888 and7,998,173, for example) except for the construction of a master cylinder224 of the hydraulic operating mechanism 220, the details of theconstructions of the hydraulic operating mechanism 220 will be omittedfor the sake of brevity, except for the constructions related to themaster cylinder 224.

As diagrammatically illustrated in FIG. 34, the hydraulic operatingmechanism 220 operates at least one of a hydraulically operatedderailleur 242 and a hydraulically operated suspension adjuster 244. Thederailleur 242 and the suspension adjuster 244 are conventional bicyclecomponents (e.g., see U.S. Pat. Nos. 7,509,888 and 7,998,173, forexample), and thus, they will not be discussed and/or illustratedherein. Thus, the hydraulic operating mechanism 220 constitutes at leastone of a shift operation device and a suspension control operationdevice.

The hydraulic operating mechanism 220 is hydraulically connected to atleast one of the derailleur 242 and the suspension adjuster 244 via ahydraulic bicycle hose structure 214. The hydraulic bicycle hosestructure 214 is identical or substantially identical to the hydraulicbrake hose structure 14 shown in FIG. 3. In view of the similaritybetween the hydraulic brake hose structure 14 and the hydraulic bicyclehose structure 214, the parts of the hydraulic bicycle hose structure214 that are identical to the parts of the hydraulic brake hosestructure 14 will be given the same reference numerals but with “200”added thereto, and the detailed description of the hydraulic bicyclehose structure 214 is omitted for the sake of brevity.

As seen in FIGS. 34 and 35, the hydraulic operating mechanism 220basically has a housing 223 with a master cylinder 224. The hydraulicoperating mechanism 220 further has a clamp 226 and first and secondlevers 228 a and 228 b (e.g., operating levers). The clamp 226 isintegrally formed with the housing 23. The first and second levers 228 aand 228 b are pivotally coupled to the housing 23. The hydraulicoperating mechanism 220 is supported on the handlebar 30 via the clamp226 in a conventional manner. The first and second levers 228 a and 228b are pivotally coupled to the housing 23 for hydraulically operating atleast one of the derailleur 242 and the suspension adjuster 244. As bestseen in FIG. 34, the hydraulic operating mechanism 220 is illustrated asa double lever indexing type of cable operating device that includes thefirst lever 228 a and the second lever 228 b. Operation of the firstlever 228 a incrementally changes (or increases) hydraulic pressure inthe hydraulic bicycle hose structure 214 in a conventional manner, whileoperation of the second lever 228 b decrementally releases (ordecreases) the hydraulic pressure in the hydraulic bicycle hosestructure 214 in a conventional manner. As a result, the hydraulicoperating mechanism 220 operates the derailleur 242 for performing gearshifting operations, or operates the suspension adjuster 24 for shiftingbetween a plurality of suspension settings, such as a rigid suspensionsetting, a compressible setting, and so forth. In particular, the firstand second levers 228 a and 228 b are operatively connected to a piston234, which is movably disposed within the master cylinder 224, such thatthe operations of the first and second levers 228 a and 228 b move thepiston 234 in a stepwise manner. Furthermore, the housing 23 has aconventional gear mechanism (not shown) that retain a position of thepiston 234 movably disposed in the master cylinder 224 at a plurality oflocations. However, the hydraulic operating mechanism 220 is not limitedto this type of hydraulic operating device. Also, the hydraulicoperating mechanism 220 can be configured to operate more than onebicycle component.

As seen in FIGS. 34 and 35, the master cylinder 224 defines a mastercylinder bore or chamber 232 that has the piston 234 reciprocallymounted in the master cylinder bore 232. The piston 234 is biased with acompression spring disposed within the master cylinder bore 232, Themaster cylinder 224 also has a hydraulic fluid reservoir 236 that is influid communication with the master cylinder bore 232. The hydraulicfluid reservoir 236 contains the hydraulic fluid (e.g., mineral oil)which is pressurized by movement of the piston 234 in the mastercylinder bore 232 in response to the pivotal movement of the first andsecond levers 228 a and 228 b. In other words, the first and secondlevers 228 a and 228 b are operatively coupled to the piston 234 formoving the piston 234 within the master cylinder bore 232 in a stepwisemanner. The master cylinder 224 has an outlet port 238 for supplying thehydraulic fluid to at least one of the derailleur 242 and the suspensionadjuster 244 via the hydraulic bicycle hose structure 214. Since theoperations of the master cylinder 224 and the piston 234 areconventional, these parts will not be discussed or shown in furtherdetail herein. The master cylinder 224 also has a hose attachmentsection 239 (e.g., an attachment portion) with an internal threaded bore224 a that is fluidly communicated with the master cylinder bore 232 viathe outlet port 238. The configurations of the master cylinder 224 areidentical or substantially identical to the master cylinder 24 shown inFIG. 1. In view of the similarity between the master cylinder 24 and themaster cylinder 224, the parts of the master cylinder 224 that areidentical to the parts of the master cylinder 24 will be given the samereference numerals but with “200” added thereto, and the detaileddescription of the master cylinder 224 is omitted for the sake ofbrevity.

As best seen in FIG. 35, the master cylinder 224 is further providedwith a rupturing insert 263. The rupturing insert 263 is identical orsubstantially identical to the rupturing insert 63 shown in FIG. 2B. inview of the similarity between the rupturing insert 63 and the rupturinginsert 263, the parts of the rupturing insert 263 that are identical tothe parts of the rupturing insert 63 will be given the same referencenumerals but with “200” added thereto, and the detailed description ofthe rupturing insert 263 is omitted for the sake of brevity. Therupturing insert 263 has a tubular end section 263 a, an annular flangesection 263 b, and a tubular body section 263 c. A longitudinalpassageway 263 d passes through the end section 263 a, the flangesection 263 b, and the body section 263 c. The rupturing insert 263 iscoupled to the outlet port 238 of the master cylinder 224 such that thelongitudinal passageway 263 d is fluidly communicated with the mastercylinder bore 232 of the master cylinder 224 to define a fluid path 276of the master cylinder 224. In other words, the rupturing insert 263 isdisposed in the vicinity of the fluid path 276, more specifically, on aleading edge of the fluid path 276 of the master cylinder 224.

The end section 263 a is formed as a needle for rupturing or puncturinga sealing material 262 of the hydraulic bicycle hose structure 214. Inparticular, the end section 263 a has a beveled distal end thatpunctures the sealing material 262 and is inserted into a passageway 256c of a tubular insert 256, which passes through a flange section 256 aand a tubular section 256 b of the tubular insert 256, in response to anend portion 250 a of a flexible tube 250 of the hydraulic bicycle hosestructure 214 being coupled to the internal threaded bore 224 a of themaster cylinder 224. In other words, the end section 263 a isdimensioned such that the end section 263 a is fittedly inserted intothe passageway 256 c of the tubular insert 256. The flange section 263 bis rested on an annular inner end face of the internal threaded bore 224a of the master cylinder 224. When the end portion 250 a of the flexibletube 250 is coupled to the master cylinder 224, the flange section 263 bis pushed against the annular inner end face of the internal threadedbore 224 a of the master cylinder 224, which securely retains therupturing insert 263 relative to the outlet port 238. The outer surfaceof the body section 263 c is fitted to the inner surface of the outletport 238. The body section 263 c is designed to be retained in theoutlet port 238. The rupturing insert 263 is constructed of a resinmaterial such as a plastic. Of course, any suitable rigid material canbe utilized for the rupturing insert 263 as needed and/or desired.

With this hydraulic operating mechanism 220, the sealing material 262 isconstructed to be ruptured or punctured with the tubular rupturinginsert 263. In particular, the sealing material 262 is physicallyruptured by the rupturing insert 263 in response to the end portion 250a of the flexible tube 250 of the hydraulic bicycle hose structure 214being fully inserted to the hose attachment section 239 of the mastercylinder 224.

In the illustrated embodiment, a hydraulic bicycle hose structure (e.g.,a hydraulic brake hose structure 14) includes a hydraulic hose (e.g., aflexible tube 50) and a first seal (e.g., a first sealing material 62 ora second sealing material 72). The hydraulic hose has a first end (e.g.,a first end portion 50 a or a second end portion 50 b) with a firstopening. The hydraulic hose is configured to be coupled to a hydrauliccomponent (e.g., a brake operating mechanism 20 or a caliper 22). Thehydraulic hose is filled with hydraulic fluid. The first seal isarranged to seal the first opening of the first end of the hydraulichose. The first seal is configured to be physically ruptured.

With this hydraulic bicycle hose structure, the first seal is physicallyruptured when the hydraulic hose is coupled to the hydraulic component.The first seal is physically ruptured by a part (e.g., a tubularrupturing insert 63 or 72) of the hydraulic component. The first seal isformed of a sheet. The sheet is formed of a foil.

With this hydraulic bicycle hose structure, the hydraulic bicycle hosestructure further includes a rupturing member (e.g., a rupturing tool170) that is configured and arranged to rupture the first seal. Thefirst seal is physically ruptured before the hydraulic hose is coupledto the hydraulic component. The first seal is physically ruptured by therupturing member in advance. The first seal is formed of a sheet. Thesheet is formed of a foil.

With this hydraulic bicycle hose structure, the hydraulic bicycle hosestructure further includes a first protective cap (e.g., a protectivecap 92 or 130) that is arranged to protect the first end that is sealedby the first seal. The first protective cap has a bore (e.g., a bore 92d or 130 d) within which the first end of the hydraulic hose with thefirst seal is disposed. The bore of the first protective cap has acylindrical inner face. The first protective cap can have a sphericalhead (e.g., a head portion 92 a). The first protective cap can have ahook portion (e.g., a hooked head portion 130 a). The first protectivecap can have a cord attachment portion (e.g., a through hole 92 c) forattaching a cord (e.g., a cord 94). The cord attachment portion has athrough hole (e.g. a through hole 92 c).

In the illustrated embodiment, a hydraulic bicycle hose structure (e.g.,a hydraulic brake hose structure 14) includes a hydraulic hose (e.g., aflexible tube 50) and a first detachable seal (e.g., a sealing material162 or a sealing plug 168). The hydraulic hose has a first end (e.g., afirst end portion 50 a or a second end portion 50 b) with a firstopening. The hydraulic hose is configured to be coupled to a hydrauliccomponent (e.g., a brake operating mechanism 20 or a caliper 22). Thehydraulic hose is filled with hydraulic fluid. The first detachable sealis arranged to seal the first opening of the first end of the hydraulichose.

With this hydraulic bicycle hose structure, the first detachable seal isdetached before the hydraulic hose is coupled to the hydrauliccomponent. The first detachable seal can be a detachable plug (e.g., asealing plug 168). The first detachable seal can be a strippable sheet(e.g., a sealing material 162). The strippable sheet has a stripping tab(e.g., a stripping tab 62 a)

While only selected embodiments have been chosen to illustrate thepresent invention, it will be apparent to those skilled in the art fromthis disclosure that various changes and modifications can be madeherein without departing from the scope of the invention as defined inthe appended claims. For example, the size, shape, location ororientation of the various components can be changed as needed and/ordesired. Components that are shown directly connected or contacting eachother can have intermediate structures disposed between them. Thefunctions of one element can be performed by two, and vice versa. Thestructures and functions of one embodiment can be adopted in anotherembodiment. It is not necessary for all advantages to be present in aparticular embodiment at the same time. Every feature which is uniquefrom the prior art, alone or in combination with other features, alsoshould be considered a separate description of further inventions by theapplicant, including the structural and/or functional concepts embodiedby such feature(s). Thus, the foregoing descriptions of the embodimentsaccording to the present invention are provided for illustration only,and not for the purpose of limiting the invention as defined by theappended claims and their equivalents.

What is claimed is:
 1. A hydraulic bicycle hose structure comprising: ahydraulic hose having a first end with a first opening, the hydraulichose being configured to be coupled to a hydraulic component, thehydraulic hose being filled with hydraulic fluid; and a first sealarranged to seal the first opening of the first end of the hydraulichose, the first seal being configured to be physically ruptured.
 2. Thehydraulic bicycle hose structure according to claim 1, wherein the firstseal is physically ruptured when the hydraulic hose is coupled to thehydraulic component.
 3. The hydraulic bicycle hose structure accordingto claim 2, wherein the first seal is physically ruptured by a part ofthe hydraulic component.
 4. The hydraulic bicycle hose structureaccording to claim 2, wherein the first seal is formed of a sheet. 5.The hydraulic bicycle hose structure according to claim 4, wherein thesheet is formed of a foil.
 6. The hydraulic bicycle hose structureaccording to claim 1, further comprising a rupturing member configuredand arranged to rupture the first seal.
 7. The hydraulic bicycle hosestructure according to claim 6, wherein the first seal is physicallyruptured before the hydraulic hose is coupled to the hydrauliccomponent.
 8. The hydraulic bicycle hose structure according to claim 6,wherein the first seal is physically ruptured by the rupturing member inadvance.
 9. The hydraulic bicycle hose structure according to claim 7,wherein the first seal is formed of a sheet.
 10. The hydraulic bicyclehose structure according to claim 9, wherein the sheet is formed of afoil.
 11. The hydraulic bicycle hose structure according to claim 1,further comprising a first protective cap arranged to protect the firstend that is sealed by the first seal.
 12. The hydraulic bicycle hosestructure according to claim 11, wherein the first protective cap has abore within which the first end of the hydraulic hose with the firstseal is disposed.
 13. The hydraulic bicycle hose structure according toclaim 12, wherein the bore of the first protective cap has a cylindricalinner face.
 14. The hydraulic bicycle hose structure according to claim11, wherein the first protective cap has a spherical head.
 15. Thehydraulic bicycle hose structure according to claim 11, wherein thefirst protective cap has a hook portion.
 16. The hydraulic bicycle hosestructure according to claim 11, wherein the first protective cap has acord attachment portion for attaching a cord.
 17. The hydraulic bicyclehose structure according to claim 16, wherein the cord attachmentportion has a through hole.
 18. A hydraulic bicycle hose structurecomprising: a hydraulic hose having a first end with a first opening,the hydraulic hose being configured to be coupled to a hydrauliccomponent, the hydraulic hose being filled with hydraulic fluid; and afirst detachable seal arranged to seal the first opening of the firstend of the hydraulic hose.
 19. The hydraulic bicycle hose structureaccording to claim 18, wherein the first detachable seal is detachedbefore the hydraulic hose is coupled to the hydraulic component.
 20. Thehydraulic bicycle hose structure according to claim 19, wherein thefirst detachable seal is a detachable plug.
 21. The hydraulic bicyclehose structure according to claim 19, wherein the first detachable sealis a strippable sheet.
 22. The hydraulic bicycle hose structureaccording to claim 21, wherein the strippable sheet has a stripping tab.